Manual Transaxle: Section

MT-1
MANUAL TRANSAXLE
C TRANSMISSION/TRANSAXLE
CONTENTS
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SECTION
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MT
Revision: May 2004 2003 Sentra
RS5F70A
PRECAUTIONS .......................................................... 4
Caution ..................................................................... 4
PREPARATION ........................................................... 5
Special Service Tools ............................................... 5
Commercial Service Tools ........................................ 7
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 9
NVH Troubleshooting Chart ................................ ..... 9
DESCRIPTION ....................................................... ... 10
Cross-sectional View .............................................. 10
DOUBLE-CONE SYNCHRONIZER .................... 10
M/T OIL .................................................................. ....11
Replacement ...........................................................11
DRAINING ............................................................11
FILLING ............................................................ ....11
Checking ............................................................. ....11
OIL LEAKAGE AND OIL LEVEL ..........................11
SIDE OIL SEAL ..................................................... ... 12
Removal and Installation ..................................... ... 12
POSITION SWITCH ............................................... ... 13
Position Switch Check ......................................... ... 13
BACK-UP LAMP SWITCH ............................... ... 13
PNP SWITCH ...................................................... 13
CONTROL LINKAGE ............................................ ... 14
TRANSAXLE GEAR CONTROL ......................... 14
STRIKING ROD OIL SEAL .............................. ... 15
TRANSAXLE ASSEMBLY ........................................ 16
REMOVAL ........................................................... 16
INSTALLATION ................................................... 19
Component Parts ................................................... 20
CASE COMPONENTS ..................................... ... 20
GEAR COMPONENTS ....................................... 21
SHIFT CONTROL COMPONENTS .................... 22
FINAL DRIVE COMPONENTS ........................ ... 23
Disassembly and Assembly ................................... 23
DISASSEMBLY ................................................... 23
ASSEMBLY ......................................................... 30
INPUT SHAFT AND GEARS ................................. ... 41
Disassembly ........................................................... 41
Inspection ............................................................... 42
GEAR AND SHAFT .......................................... ... 42
SYNCHRONIZERS .......................................... ... 43
BEARING ............................................................ 44
Assembly ................................................................ 44
MAINSHAFT AND GEARS .................................... ... 48
Disassembly ........................................................... 48
Inspection ............................................................... 50
GEAR AND SHAFT .......................................... ... 50
SYNCHRONIZERS .......................................... ... 50
BEARING ............................................................ 51
Assembly ................................................................ 52
FINAL DRIVE ......................................................... ... 58
Pre-inspection ...................................................... ... 58
DIFFERENTIAL CASE SIDE ............................ ... 58
Disassembly ........................................................... 58
Inspection ............................................................... 59
GEAR, WASHER, SHAFT AND CASE ............ ... 59
BEARING ............................................................ 59
Assembly ................................................................ 59
SHIFT CONTROL .................................................. ... 62
Inspection ............................................................... 62
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 63
General Specifications ......................................... ... 63
TRANSAXLE ....................................................... 63
FINAL GEAR .................................................... ... 63
Gear End Play ........................................................ 64
Clearance Between Baulk Ring and Gear .............. 64
3RD, 4TH, 5TH, REVERSE BAULK RING .......... 64
1ST AND 2ND BAULK RING ........................... ... 64
Available Snap Rings ............................................. 64
SNAP RING ...................................................... ... 64
Available C-rings ................................................. ... 64
4TH INPUT GEAR C-RING .............................. ... 64
5TH INPUT GEAR REAR C-RING ................... ... 65
MAINSHAFT C-RING ....................................... ... 65
Available Adjusting Shims ................................... ... 65
INPUT SHAFT REAR BEARING ADJUSTING
MT-2 Revision: May 2004 2003 Sentra
SHIM ................................................................. ... 65
MAINSHAFT ADJUSTING SHIM ........................ 66
MAINSHAFT REAR BEARING ADJUSTING
SHIM ................................................................. ... 66
Available Thrust Washer ......................................... 67
MAINSHAFT THRUST WASHER ..................... ... 67
Available Washers .................................................. 67
DIFFERENTIAL SIDE GEAR THRUST WASHER
... 67
Available Shims Differential Side Bearing Pre-
load and Adjusting Shim ......................................... 68
BEARING PRELOAD .......................................... 68
DIFFERENTIAL SIDE BEARING ADJUSTING
SHIMS .............................................................. ... 68
RS5F51A
PRECAUTIONS ......................................................... 69
Cautions .............................................................. ... 69
PREPARATION ...................................................... ... 70
Special Service Tools ............................................. 70
Commercial Service Tools ...................................... 72
TROUBLESHOOTING .............................................. 73
NVH Troubleshooting Chart ................................. ... 73
DESCRIPTION .......................................................... 74
Cross-sectional View .............................................. 74
DOUBLE-CONE SYNCHRONIZER ................. ... 75
REVERSE GEAR ................................................ 75
M/T OIL ................................................................... ... 76
Replacement ....................................................... ... 76
DRAINING ........................................................... 76
FILLING ............................................................... 76
Checking .............................................................. ... 76
OIL LEAKAGE AND OIL LEVEL ...................... ... 76
SIDE OIL SEAL ...................................................... ... 77
Removal and Installation ........................................ 77
REMOVAL ........................................................... 77
INSTALLATION .................................................... 77
POSITION SWITCH ............................................... ... 78
Checking .............................................................. ... 78
BACK-UP LAMP SWITCH ................................ ... 78
PARK/NEUTRAL POSITION SWITCH ................ 78
CONTROL LINKAGE ............................................. ... 79
Removal and Installation of Control Device and
Cable ................................................................... ... 79
Cable Adjustment ................................................... 80
AIR BREATHER HOSE .......................................... ... 81
TRANSAXLE ASSEMBLY ........................................ 82
REMOVAL ........................................................... 82
INSTALLATION .................................................... 83
Component Parts ................................................. ... 84
CASE AND HOUSING COMPONENTS ........... ... 84
GEAR COMPONENTS ..................................... ... 85
SHIFT CONTROL COMPONENTS .................. ... 87
FINAL DRIVE COMPONENTS ......................... ... 88
Disassembly and Assembly .................................... 88
DISASSEMBLY ....................................................88
ASSEMBLY ..........................................................92
Adjustment ..............................................................98
INPUTSHAFT END PLAY ................................. ...98
DIFFERENTIAL SIDE BEARING PRELOAD .... ...99
MAINSHAFT END PLAY ................................... .100
REVERSE IDLER GEAR END PLAY ............... .101
INPUT SHAFT AND GEARS ...................................103
Disassembly and Assembly ..................................103
DISASSEMBLY ..................................................103
INSPECTION AFTER DISASSEMBLY ..............104
ASSEMBLY ........................................................105
MAINSHAFT AND GEARS .................................... . 110
Disassembly and Assembly .................................. 110
DISASSEMBLY .................................................. 110
INSPECTION AFTER DISASSEMBLY .............. 111
ASSEMBLY ........................................................ 113
REVERSE IDLER SHAFT AND GEARS ............... . 118
Disassembly and Assembly .................................. 118
DISASSEMBLY .................................................. 118
ASSEMBLY ........................................................ 119
FINAL DRIVE ..........................................................120
Disassembly and Assembly ..................................120
PRE-INSPECTION ............................................120
DISASSEMBLY ..................................................120
INSPECTION AFTER DISASSEMBLY ..............121
ASSEMBLY ........................................................121
SHIFT CONTROL ................................................... .124
Inspection ............................................................. .124
SHIFT FORK ..................................................... .124
SERVICE DATA AND SPECIFICATIONS (SDS) ....125
General Specifications ......................................... .125
TRANSAXLE ......................................................125
FINAL GEAR ......................................................125
Gear End Play ...................................................... .126
Clearance Between Baulk Ring and Gear ............126
3RD, 4TH, 5TH & REVERSE BAULK RING ......126
1ST AND 2ND DOUBLE BAULK RING ............ .126
Available Snap Rings ............................................126
INPUT SHAFT SPACER ................................... .126
5TH MAIN GEAR .............................................. .126
Available C-rings ...................................................127
MAINSHAFT C-RING ....................................... .127
Available Thrust Washers .....................................127
INPUT SHAFT THRUST WASHER .................. .127
.127
Available Adjusting Shims .....................................128
MAINSHAFT ADJUSTING SHIM ...................... .128
SHIM ..................................................................128
SHIM ..................................................................128
REVERASE IDLER GEAR ADJUSTING SHIM .129
Available Shims ....................................................129
BEARING PRELOAD .........................................129
SHIM(S) .............................................................129
MT-3
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MT
RS6F51H
PRECAUTIONS ...................................................... 130
Caution ................................................................. 130
PREPARATION ....................................................... 131
Special Service Tools ........................................... 131
Commercial Service Tools .................................... 133
TROUBLESHOOTING ............................................ 134
NVH Troubleshooting Chart ................................ . 134
DESCRIPTION ....................................................... . 135
Cross-sectional View ............................................ 135
DOUBLE-CONE SYNCHRONIZER .................. 136
REVERSE GEAR .............................................. 136
M/T OIL .................................................................. . 137
Replacement ........................................................ 137
DRAINING ......................................................... 137
FILLING ............................................................ . 137
Checking ............................................................. . 137
OIL LEAKAGE AND OIL LEVEL ....................... 137
SIDE OIL SEAL ..................................................... . 138
Removal and Installation ..................................... . 138
REMOVAL ......................................................... 138
INSTALLATION ................................................. 138
POSITION SWITCH ............................................... . 139
Checking ............................................................. . 139
BACK-UP LAMP SWITCH ............................... . 139
PARK/NEUTRAL POSITION SWITCH ............ . 139
CONTROL LINKAGE ............................................ . 140
Removal and Installation of Control Device and
Cable .................................................................... 140
Cable Adjustment ................................................. 141
AIR BREATHER HOSE ......................................... . 142
TRANSAXLE ASSEMBLY ...................................... 143
REMOVAL ......................................................... 143
INSTALLATION ................................................. 144
Component Parts ................................................. 145
CASE AND HOUSING COMPONENTS .......... . 145
GEAR COMPONENTS ..................................... 146
SHIFT CONTROL COMPONENTS .................. 148
FINAL DRIVE COMPONENTS ........................ . 149
Disassembly and Assembly ................................. 149
DISASSEMBLY ................................................. 149
ASSEMBLY ....................................................... 153
Adjustment ........................................................... 160
INPUTSHAFT END PLAY ................................. 160
DIFFERENTIAL SIDE BEARING PRELOAD .... 161
MAINSHAFT END PLAY .................................. . 162
REVERSE IDLER GEAR END PLAY ................ 163
INPUT SHAFT AND GEARS ................................. . 165
Disassembly and Assembly ................................. . 165
DISASSEMBLY ................................................ . 165
ASSEMBLY ...................................................... . 167
MAINSHAFT AND GEARS .................................... . 172
DISASSEMBLY ................................................ . 172
ASSEMBLY ...................................................... . 175
REVERSE IDLER SHAFT AND GEARS ............... . 180
DISASSEMBLY ................................................ . 180
ASSEMBLY ...................................................... . 181
FINAL DRIVE ......................................................... . 182
DISASSEMBLY ................................................ . 182
ASSEMBLY ...................................................... . 182
SHIFT CONTROL .................................................. . 184
Inspection ............................................................. 184
SHIFT FORK .................................................... . 184
SERVICE DATA AND SPECIFICATIONS (SDS) .... 185
General Specifications ......................................... . 185
TRANSAXLE ..................................................... 185
FINAL GEAR .................................................... . 186
Gear End Play ...................................................... 186
Clearance Between Baulk Ring and Gear ............ 186
3RD, 4TH, 5TH, 6TH & REVERSE BAULK RING . 186
1ST AND 2ND DOUBLE BAULK RING ............. 186
Available Snap Rings ........................................... 187
6TH BUSHING ................................................. . 187
Available C-rings ................................................. . 187
MAINSHAFT C-RING ....................................... . 187
Available Thrust Washers ..................................... 187
INPUT SHAFT THRUST WASHER .................. . 187
Available Adjusting Shims ................................... . 188
MAINSHAFT ADJUSTING SHIM ..................... . 188
SHIM ................................................................ . 188
SHIM ................................................................ . 188
REVERASE IDLER GEAR ADJUSTING SHIM . 189
6TH MAIN GEAR ADJUSTING SHIM ............... 189
Available Shims ................................................... . 189
BEARING PRELOAD ........................................ 189
SHIM(S) ............................................................ . 189
MT-4
[RS5F70A]
PRECAUTIONS
PRECAUTIONS PFP:00001
Caution ECS005TD
G Do not reuse transaxle oil, once it has been drained.
G Check oil level or replace oil with vehicle on level ground.
G During removal or installation, keep inside of transaxle clear of dust or dirt.
G Check for the correct installation status prior to removal or disassembly. If mating marks are required, be
certain they do not interfere with the function of the parts they are applied to.
G In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, use it.
G Be careful not to damage sliding surfaces and mating surfaces.
PREPARATION
MT-5
[RS5F70A]
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PREPARATION PFP:00002
Special Service Tools ECS005TE
The actual shapes of the Kent-Moore tools may differ from those of the special service tools illustrated here.
Tool number
(Kent-Moore No.)
Tool name
Description
KV38107700
(J39027)
Preload adapter
Measuring turning torque of final drive assem-
bly
Measuring total turning torque
Measuring clearance between side gear and
differential case with washer
Selecting differential side bearing adjusting
shim [Use with KV38106000 (J34291-B).]
KV38106000
(J34291-B)
Height gauge adapter
(differential side bearing)
Selecting differential side bearing adjusting
shim [Use with KV38107700 (J39027).]
a: 140 mm (5.51 in)
b: 40 mm (1.57 in)
c: 16 mm (0.63 in) dia.
d: M8 1.25P
KV32101000
(J25689-A)
Pin punch
Removing and installing retaining pin
Removing and installing lock pin
Removing selector shaft
Removing welch plug
a: 4 mm (0.16 in) dia.
KV31100300
(J25689-A)
Pin punch
Removing and installing retaining pin
a: 4.5 mm (0.177 in) dia.
ST30031000
(J22912-O1)
Puller
Removing 3rd, 5th input gear
Removing 3rd & 4th and 5th & Rev synchro-
nizer hub
Removing mainshaft rear bearing
Removing 2nd gear, 5th gear bush
Removing 1st & 2nd synchronizer hub, 1st
and 4th main gear
Removing and installing differential side bear-
ing
a: 90 mm (3.54 in) dia.
b: 50 mm (1.97 in) dia.
ST30021000
(J22912-O1)
Puller
Removing input shaft front and rear bearing
Installing input shaft front and rear bearing
Installing 5th input gear, 3rd main gear and
4th main gear
Installing 1st & 2nd, 3rd & 4th and 5th & Rev
synchronizer hub
Installing 2nd gear bush, 5th gear bush, Rev
gear bush
Installing mainshaft rear bearing
a: 110 mm (4.33 in) dia.
b: 68 mm (2.68 in) dia.
NT087
NT418
NT410
NT410
NT411
NT411
MT-6
[RS5F70A]
PREPARATION
ST33061000
(J8107-2)
Drift
Removing differential side bearing
a: 39 mm (1.54 in) dia.
b: 29.5 mm (1.16 in) dia.
ST33290001
(J34286)
Puller
G Removing idler gear bearing outer race
a: 250 mm (9.84 in)
b: 160 mm (6.30 in)
ST33230000
(J25805-O1)
Drift
Removing differential oil seal
Installing differential side bearing
a: 51 mm (2.01 in) dia.
b: 28.5 mm (1.122 in) dia.
ST30720000
(J25405)
Drift
Installing differential side bearing outer race
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
ST22350000
(J25678-O1)
Drift
Installing input shaft front and rear bearing
a: 34 mm (1.34 in) dia.
b: 28 mm (1.10 in) dia.
ST22452000
(J34335)
Drift
Installing 3rd and 4th main gear
Installing 5th gear bush
Installing 5th & Rev synchronizer hub
Installing Rev gear bush
a: 45 mm (1.77 in) dia.
b: 36 mm (1.42 in) dia.
ST37750000
(J34335)
Drift
Installing input shaft oil seal
Installing 5th synchronizer
Installing 5th main gear
Installing 3rd & 4th synchronizer hub
Installing striking rod oil seal
Installing clutch housing dust seal
a: 40 mm (1.57 in) dia.
b: 31 mm (1.22 in) dia.
Tool number
(Kent-Moore No.)
Tool name
Description
NT073
NT414
NT084
NT115
NT065
NT065
NT065
PREPARATION
MT-7
[RS5F70A]
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MT
Commercial Service Tools ECS005TF
ST30621000
(J35869)
Drift
[Use with ST30611000 (J25742-1).]
a: 79 mm (3.11 in) dia.
b: 59 mm (2.32 in) dia.
ST30611000
(J25742-1)
Drift handle
[Use with ST30621000 (J35869).]
a: 15 mm (0.59 in)
b: 335 mm (13.19 in)
c: 25 mm (0.98 in) dia.
d: M12 1.5P
Tool number
(Kent-Moore No.)
Tool name
Description
NT073
NT419
Tool name Description
Drift Installing differential side bearing inner race
a: 56 mm (2.20 in) dia.
b: 50.5 mm (1.988 in) dia.
Drift Removing input shaft rear bearing
Removing mainshaft rear bearing
a: 22 mm (0.87 in) dia.
b: 16 mm (0.63 in) dia.
Drift Installing differential oil seal
(Transaxle case side)
a: 58 mm (2.28 in) dia.
b: 50 mm (1.97 in) dia.
Drift Installing differential oil seal
(Clutch housing side)
a: 54 mm (2.13 in) dia.
b: 50 mm (1.97 in) dia.
Drift Installing 2nd gear bush
a: 38 mm (1.50 in) dia.
b: 33 mm (1.30 in) dia.
NT065
NT065
NT065
NT065
NT065
MT-8
[RS5F70A]
PREPARATION
Drift Installing 3rd & 4th and 1st & 2nd synchroniz-
er hub
Installing mainshaft front bearing
a: 50 mm (1.97 in) dia.
b: 41 mm (1.61 in) dia.
Drift Installing input shaft oil seal
Installing 5th input gear
a: 39 mm (1.54 in) dia.
b: 30 mm (1.18 in) dia.
NT065
NT065
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
MT-9
[RS5F70A]
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NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003
NVH Troubleshooting Chart ECS005TG
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts.
Reference page
M
T
-
1
1
M
T
-
1
1
M
T
-
1
1
M
T
-
2
0
M
T
-
1
4
M
T
-
2
2
M
T
-
2
1
,

M
T
-
2
3
Suspected Parts (possible cause)
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Symptom
Noise 1 2 3 3
Oil leakage 3 1 2 2 2
Hard to shift or will not shift 1 1 2 3 3
Jumps out of gear 1 2 3 3
MT-10
[RS5F70A]
DESCRIPTION
DESCRIPTION PFP:00000
Cross-sectional View ECS005TH
DOUBLE-CONE SYNCHRONIZER
Double-cone synchronizer is used for 1st and 2nd gears to reduce
operating force of the shift lever.
WCIA0017E
SMT837DA
M/T OIL
MT-11
[RS5F70A]
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M/T OIL PFP:KLD20
Replacement ECS005TI
DRAINING
1. Start the engine and let it run to warm up the transaxle.
2. Stop the engine. Remove drain plug and drain oil.
3. Set a gasket on the drain plug and install it on the transaxle.
CAUTION:
Do not reuse gasket.
FILLING
1. Remove filler plug. Fill with new oil until oil level reaches the specified limit near filler plug mounting hole.
2. After refilling oil, check oil level. Set a new gasket on the filler plug, then install it in the transaxle body.
CAUTION:
Checking ECS005TJ
OIL LEAKAGE AND OIL LEVEL
G Check that oil is not leaking from transaxle.
G Check oil level from filler plug mounting hole as shown.
CAUTION:
Never start engine while checking oil level.
G Set a new gasket on the filler plug and install it in the transaxle
body.
CAUTION:
Drain plug : 10 - 19 Nm (1.0 - 2.0 kg-m, 87 - 173 in-lb)
SMA145AA
Oil grade : API GL-4
Capacity (reference) : Approximately 3.0 (3 1/8 qt)
Filler plug : 10 - 19 Nm (1.0 - 2.0 kg-m, 87 - 173 in-lb)
Filler plug : 10 - 19 Nm (1.0 - 2.0 kg-m, 87 - 173 in-lb)
SMA066C
MT-12
[RS5F70A]
SIDE OIL SEAL
SIDE OIL SEAL PFP:32113
Removal and Installation ECS005TK
1. Remove drain plug and drain the oil from transaxle. Refer to MT-11, "DRAINING" .
2. Remove drive shafts. Refer to FAX-14, "Removal" .
3. Remove differential oil seal using Tool.
4. Install differential oil seal with a suitable tool.
G Apply multi-purpose grease to seal lip of oil seal before install-
ing.
5. Install drive shafts. Refer to FAX-16, "Installation" .
G Install differential oil seal so that dimensions A and B are
within specifications.
Unit: mm (in)
6. Refill the transaxle oil and install the drain plug with a new gasket. Refer to MT-11, "FILLING" .
SMT563A
SMT126DB
Model Dimension "A" Dimension "B"
QG18DE
(RS5F70A)
0.5 (0.020) or less 5.5 - 6.5 (0.217 - 0.256)
WCIA0001E
POSITION SWITCH
MT-13
[RS5F70A]
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A
B
MT
POSITION SWITCH PFP:32005
Position Switch Check ECS005TL
NOTE:
For removal and installation of the switches. Refer to MT-20, "CASE COMPONENTS" .
BACK-UP LAMP SWITCH
G Check continuity.
PNP SWITCH
G Check continuity.
Gear position Continuity
Reverse Yes
Except reverse No
SMT715BD
Neutral Yes
Except neutral No
MT-14
[RS5F70A]
CONTROL LINKAGE
CONTROL LINKAGE PFP:34103
Removal and Installation ECS005TM
TRANSAXLE GEAR CONTROL
Refer to the illustration for the removal and installation procedure.
1. Control lever knob 2. Boot 3. Finisher
4. Control lever bracket 5. Socket 6. Control lever
7. O-ring 8. O-ring 9. Ring spring
10. Bearing seat 11. Ring spring 12. Seat
13. Return spring 14. Control rod 15. Bushing
16. Collar 17. Bushing 18. Bracket
19. Bushing 20. Collar 21. Washer
22. Support rod bracket 23. Support rod
WCIA0135E
CONTROL LINKAGE
MT-15
[RS5F70A]
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MT
STRIKING ROD OIL SEAL
1. Remove transaxle control rod from yoke.
2. Remove retaining pin of yoke using Tool.
G Be careful not to damage boot.
3. Remove the boot.
4. Remove striking rod oil seal with a suitable tool.
5. Install striking rod oil seal using Tool.
G Apply multi-purpose grease to the seal lip of the oil seal
before installing.
6. Install the boot.
7. Install yoke and retaining pin.
8. Connect the transaxle control rod to the yoke.
SMT143DB
SMT566A
SMT570AA
MT-16
[RS5F70A]
TRANSAXLE ASSEMBLY
TRANSAXLE ASSEMBLY PFP:32010
Removal and Installation ECS005TN
REMOVAL
1. Remove battery negative terminal.
2. Remove air cleaner and air duct.
3. Remove clutch operating cylinder from transaxle. Refer to CL-11, "Removal" .
4. Disconnect back-up lamp switch, VSS sensor, PNP switch, and ground harness connectors.
5. Remove starter motor from transaxle. Refer to SC-20,
"Removal" .
WMT009
WMT010
WCIA0006E
TRANSAXLE ASSEMBLY
MT-17
[RS5F70A]
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6. Remove air breather hose.
7. Remove shift control rod and support rod from transaxle.
8. Remove the drain plug and drain gear oil from transaxle.
9. Remove the drive shafts from the transaxle. Refer to FAX-14, "Removal" .
10. Support engine by placing a jack under oil pan as shown.
CAUTION:
Do not place jack under oil pan drain plug.
SMT132D
WMT005
SMT659B
MT-18
[RS5F70A]
TRANSAXLE ASSEMBLY
11. Remove LH side and rear side mounting bolts.
12. Remove lower housing bolts.
13. Remove bolts securing transaxle.
14. Lower transaxle while supporting it with a jack.
WMT007
SMT658B
TRANSAXLE ASSEMBLY
MT-19
[RS5F70A]
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INSTALLATION
Installation is in the reverse order of removal.
G Tighten starter motor to transaxle bolts to specification.
G Tighten LH and rear mounts to specification.
G Install transaxle to engine, tighten the bolts to specification.
*: With gussets
Starter motor to transaxle bolts : 31 - 42 Nm (3.2 - 4.3 kg-m, 23 - 31 ft-lb)
Bolt No.
Tightening torque
Nm (kg-m, ft-lb)
" "mm (in)
1 30 - 40 (3.1 - 4.1, 22 - 30) 70 (2.76)
2 30 - 40 (3.1 - 4.1, 22 - 30) 80 (3.15)
3 30 - 40 (3.1 - 4.1, 22 - 30) 30 (1.18)
4* 16 - 21 (1.6 - 2.1, 12 - 15) 25 (0.98)
Front gusset A to engine 30 - 40 (3.1 - 4.1, 22 - 30) 20 (0.79)
Rear gusset B to engine 16 - 21 (1.6 - 2.1, 12 - 15) 16 (0.63)
SMT930D
MT-20
[RS5F70A]
TRANSAXLE ASSEMBLY
Component Parts ECS005TO
CASE COMPONENTS
1. Clutch housing 2. Dust seal 3. Oil pocket
4. Check plug 5. Input shaft oil seal 6. Oil channel
7. Mainshaft front bearing 8. Bearing retainer 9. Reverse idler gear front thrust
washer
10. Reverse idler gear 11. Reverse idler gear bearing 12. Reverse idler gear rear thrust
washer
13. O-ring 14. Reverse idler gear shaft 15. Snap ring
16. Back-up lamp switch 17. Filler plug 18. Side cover gasket
19. Side cover 20. Welch plug 21. Mainshaft bearing snap ring
22. Mainshaft rear bearing adjusting
shim
23. O-ring 24. Rear cover
25. Differential oil seal 26. Drain plug 27. PNP switch
28. Transmission case 29. Oil gutter 30. Welch plug
31. Boot 32. Striking rod oil seal 33. Welch plug
34. Differential oil seal 35. O-ring 36. Speedometer pinion
WMT014
TRANSAXLE ASSEMBLY
MT-21
[RS5F70A]
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GEAR COMPONENTS
1. Reverse idler gear front thrust
washer
2. Reverse idler gear 3. Reverse idler gear bearing
4. Reverse idler gear rear thrust
washer
5. O-ring 6. Reverse idler gear shaft
7. Snap ring 8. Input shaft front bearing 9. Input shaft
10. 3rd gear needle bearing 11. 3rd input gear 12. 3rd gear baulk ring
13. Coupling sleeve 14. Spread spring 15. Shifting insert
16. 3rd & 4th synchronizer hub 17. Spread spring 18. 4th gear C-ring
19. 4th gear needle bearing 20. 4th gear baulk ring 21. 4th input gear
22. 5th gear front C-ring 23. 5th input gear 24. 5th gear rear C-ring
25. C-ring holder 26. Input shaft rear bearing 27. Oil channel
28. Input shaft rear bearing adjusting
shim
29. Mainshaft front bearing 30. Mainshaft
31. 1st gear needle bearing 32. 1st main gear 33. 1st inner baulk ring
34. 1st synchronizer cone 35. 1st outer baulk ring 36. 1st & 2nd synchronizer hub
37. Coupling sleeve 38. Insert spring 39. 2nd gear bushing
40. 2nd gear needle bearing 41. 2nd gear outer baulk ring 42. 2nd gear synchronizer cone
43. 2nd inner baulk ring 44. 2nd main gear 45. 3rd main gear
46. Spacer 47. Mainshaft adjusting shim 48. 4th main gear
49. 5th gear bushing 50. 5th gear needle bearing 51. 5th main gear
52. 5th gear baulk ring 53. Spread spring 54. Shifting insert
55. 5th & reverse synchronizer hub 56. Spread spring 57. Coupling sleeve
58. Reverse gear bushing 59. Reverse gear needle bearing 60. Reverse gear baulk ring
61. Reverse main gear 62. Sub-gear 63. Sub-gear washer
64. Snap ring 65. Mainshaft thrust washer 66. Mainshaft rear bearing
67. Mainshaft C-ring 68. C-ring holder 69. Snap ring
SMT641DA
MT-22
[RS5F70A]
TRANSAXLE ASSEMBLY
SHIFT CONTROL COMPONENTS
1. Clutch housing 2. 3rd & 4th bracket 3. 3rd & 4th shift fork
4. Retaining pin 5. Check ball 6. Check pin
7. Check spring 8. Check plug 9. Stopper ring
10. 3rd & 4th fork rod 11. Selector shaft pin 12. Selector
13. 5th & reverse bracket 14. Reverse switch bracket 15. Retaining pin
16. 5th & reverse shift fork 17. Interlock plunger 18. Check ball
19. Interlock pin 20. Stopper ring 21. 5th & reverse fork rod
22. Striking lever 23. Retaining pin 24. 1st & 2nd bracket
25. 1st & 2nd shift fork 26. Check ball 27. 1st & 2nd fork rod
28. Transaxle case 29. Check ball 30. Check spring
31. Check plug 32. Select check leaf spring 33. Return spring
34. Steel ball 35. Reverse gate 36. Return bearing
37. Selector arm 38. Bushing 39. Welch plug
40. Selector shaft 41. Striking yoke 42. Retaining pin
43. Striking rod 44. Dust boot 45. Striking rod oil seal
46. Welch plug
WMT015
TRANSAXLE ASSEMBLY
MT-23
[RS5F70A]
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FINAL DRIVE COMPONENTS
Disassembly and Assembly ECS005TP
DISASSEMBLY
Transaxle Case
1. Remove back-up lamp switch, PNP switch, drain plug, and filler
plug from transaxle case.
1. Differential side bearing adjusting
shim
2. Differential side bearing outer race 3. Differential side bearing
4. Final gear 5. Differential case 6. Speedometer drive gear
7. Speedometer stopper 8. Differential side bearing 9. Differential side bearing outer race
10. Pinion mate thrust washer 11. Pinion mate gear 12. Side gear thrust washer
13. Side gear 14. Pinion mate shaft 15. Lock pin
WCIA0003E
WMT023
MT-24
[RS5F70A]
TRANSAXLE ASSEMBLY
2. Remove snap ring from reverse idler shaft as shown.
3. Remove side cover and rear cover from case.
4. Remove O-ring and mainshaft bearing adjusting shim.
5. Remove reverse idler gear shaft.
a. Attach bolt (M6) to thread of reverse idler gear shaft end as
shown.
b. Pull out the attached bolt (M6), and remove reverse idler gear
shaft from case.
6. Remove reverse idler gear, thrust washer (front, rear), and bearing from case.
7. Remove mainshaft rear bearing snap ring from case.
8. Remove check plugs, springs, and check balls from case.
SMT644D
SMT645D
SMT646D
SMT647D
TRANSAXLE ASSEMBLY
MT-25
[RS5F70A]
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9. Remove transaxle case mounting bolts.
10. Remove input shaft rear bearing adjusting shim from transaxle case.
11. Remove oil gutter from transaxle case.
12. Remove differential side bearing outer race and adjusting shim
from transaxle case using Tool.
13. Remove differential oil seal from transaxle case using Tool.
SMT649D
SMT650D
SMT651DA
SMT653DA
MT-26
[RS5F70A]
TRANSAXLE ASSEMBLY
14. Remove welch plugs from transaxle case using Tool.
Clutch Housing
1. Remove transaxle case from clutch housing.
2. Remove check plugs, check springs, check pins, and check
balls from housing.
3. Remove 3rd & 4th bracket retaining pin using Tool.
4. Remove 3rd & 4th shift fork stopper ring.
5. Remove 3rd & 4th fork rod.
6. Remove 3rd & 4th shift fork and bracket.
SMT839DA
SMT654D
SMT656DA
SMT655D
TRANSAXLE ASSEMBLY
MT-27
[RS5F70A]
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7. Remove interlock plunger and check ball.
8. Remove 5th & reverse bracket stopper ring.
9. Remove retaining pins from 5th & reverse shift fork and 5th &
reverse bracket using Tool.
10. Remove 5th & reverse fork rod.
11. Remove interlock pin from 5th & reverse fork rod using Tool.
12. Remove reverse switch bracket and 5th & reverse bracket.
13. Remove check ball from housing.
14. Remove retaining pin for 1st & 2nd shift fork and 1st & 2nd
bracket using Tool.
15. Remove 1st & 2nd fork rod.
16. Remove 5th & reverse and 1st & 2nd shift forks, and 1st & 2nd bracket.
17. Remove both input shaft and mainshaft assemblies from hous-
ing.
SMT658D
SMT657DA
SMT659DA
SMT660D
MT-28
[RS5F70A]
TRANSAXLE ASSEMBLY
18. Remove final drive assembly from housing.
19. Remove oil pocket from housing.
20. Remove mainshaft bearing retainer from housing.
21. Cut off oil channel using a cutter as shown.
22. Remove mainshaft front bearing from housing using Tool.
23. Using a magnet or other suitable tool, remove selector pin from
selector shaft.
24. Remove selector shaft and plug, then remove selector using
Tool.
SMT661D
SMT662D
SMT663DA
SMT664D
SMT665DA
TRANSAXLE ASSEMBLY
MT-29
[RS5F70A]
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25. Remove reamer bolts, then remove select check leaf spring,
return spring, steel ball, reverse gate, selector arm, bearing, and
bushing.
CAUTION:
Be careful not to lose the steel ball.
26. Remove retaining pin and plug from striking lever using Tool.
27. Remove striking rod, then striking lever from housing.
28. Using a flat-head screwdriver or other suitable tool, remove dust
seal, input shaft oil seal, and striking rod oil seal from housing.
CAUTION:
When removing dust and oil seals, be careful not to damage
mounting surfaces of dust seal and oil seal.
29. Remove differential oil seal from housing using Tool.
SMT666DA
SMT667DA
SMT668D
WMT021
MT-30
[RS5F70A]
TRANSAXLE ASSEMBLY
30. Remove differential side outer race from housing using Tool.
ASSEMBLY
Clutch Housing
1. Hammer the new striking rod oil seal into clutch housing as far
as it will go using Tool.
CAUTION:
Do not reuse striking rod oil seal.
2. Hammer the differential oil seal into clutch housing with a suit-
able tool until it becomes flush with clutch housing end face.
CAUTION:
Do not reuse differential oil seal.
3. Hammer input shaft oil seal into clutch housing as far as it will go
with a suitable tool.
CAUTION:
Do not reuse input shaft oil seal.
SMT670DA
SMT722DA
SMT723DA
SMT724DA
TRANSAXLE ASSEMBLY
MT-31
[RS5F70A]
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4. Hammer the dust seal into clutch housing as far as it will go
using Tool.
CAUTION:
Do not reuse dust seal.
5. Install outer race of differential side bearing using Tool.
6. Install new oil channel (mainshaft).
CAUTION:
Pay attention to installation direction of oil channel.
7. Align the notches on mainshaft front bearing and transaxle case.
Then, install mainshaft front bearing with a suitable tool.
8. Install mainshaft bearing retainer, tighten bolt to specification.
SMT725DA
SMT726DA
SMT727D
SMT728DA
SMT729D
MT-32
[RS5F70A]
TRANSAXLE ASSEMBLY
9. Attach boot, striking rod, and striking lever to clutch housing.
Install new retaining pin for striking lever using Tool.
CAUTION:
G Before installing striking rod, wrap the end with a vinyl
tape or similar product to prevent oil seal from being
damaged.
G Do not reuse retaining pin.
10. Hammer the new welch plug (striking lever side) with a general-
purpose drift [OD: 12 mm (0.47 in)].
CAUTION:
Do not reuse welch plug.
11. Install selector, selector shaft, and selector shaft pin into clutch
housing.
12. Hammer the new welch plug (selector shaft side) with a general-
purpose drift [OD: 12 mm (0.47 in)].
CAUTION:
Do not reuse welch plug.
13. Install select check leaf spring, return spring, steel ball, reverse
gate, selector arm, bushing, and return bearing.
SMT667DA
SMT730D
SMT731D
SMT732D
SMT733DA
TRANSAXLE ASSEMBLY
MT-33
[RS5F70A]
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14. Tighten the two reamer bolts to specification.
CAUTION:
Use correct reamer bolts for each installation point,
because each bolt has a different length.
15. Install oil pocket.
16. Install differential assembly, input shaft assembly, and mainshaft
assembly into clutch housing.
CAUTION:
Be careful not to damage input shaft oil seal during installa-
tion of input shaft assembly.
17. Install 5th & reverse shift fork.
18. Install 1st & 2nd shift fork, bracket, and fork rod.
19. Install retaining pin for 1st & 2nd bracket using Tool.
CAUTION:
Do not reuse retaining pin.
20. Install two check balls.
SMT734D
SMT735D
SMT736D
SMT659DB
MT-34
[RS5F70A]
TRANSAXLE ASSEMBLY
21. Install interlock pin into 5th & reverse fork rod using Tool.
22. Install reverse switch bracket, 5th & reverse bracket, and fork
rod.
23. Install new retaining pin for 5th & reverse shift fork and reverse
switch bracket using Tool.
CAUTION:
24. Install 5th & reverse bracket stopper ring.
CAUTION:
Do not reuse stopper pin.
25. Install check ball and interlock plunger.
26. Install 3rd & 4th shift fork, bracket, and fork rod.
27. Install 3rd & 4th bracket retaining pin using Tool.
CAUTION:
28. Install 3rd & 4th shift fork stopper ring.
CAUTION:
Do not reuse stopper ring.
29. Install check ball, check pin, and check spring, and apply Anaerobic Liquid Gasket or equivalent onto the
check plug. Then, tighten the check plug to specification.
Refer to MT-22, "SHIFT CONTROL COMPONENTS" .
Transaxle Case
1. Insert differential oil seal into differential case with a suitable tool
until it becomes flush with case end face.
SMT657DB
SMT656DB
SMT655D
SMT737DA
TRANSAXLE ASSEMBLY
MT-35
[RS5F70A]
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2. Install welch plug into transaxle case with a suitable tool.
3. Calculate dimension N (thickness of adjusting shim) using the
following procedure to satisfy specification of end play for differ-
ential side bearing.
Use the "Available Shims" table for the available shim sizes. Refer to MT-68, "Available Shims Differen-
tial Side Bearing Preload and Adjusting Shim" .
a. Using dial gauge and scale, measure dimension N1 between
clutch housing case end face and mounting face of adjusting
shim.
b. Install outer race onto differential side bearing on final gear side. Holding the outer race horizontally by
hand, rotate the final gear five times or more (for smooth movement of bearing roller).
c. Using dial gauge and scale as shown, measure dimension N2
between differential side bearing outer race and transaxle case
end face.
SMT739D
End play : 0.15 - 0.21 mm (0.0059 - 0.0083 in)
Dimension N = (N1 N2) + End play
N : Thickness of adjusting shim
N1 : Distance between clutch housing
case end face and mounting face
of adjusting shim
N2 : Distance between differential side
bearing and transaxle case
SMT740D
SMT741D
SMT742D
MT-36
[RS5F70A]
TRANSAXLE ASSEMBLY
4. Install the selected shim and bearing outer race using Tool.
5. Measure the turning torque of the final drive assembly using
Tool.
G When the old bearing is used again, turning torque will
be slightly less than the above.
G Make sure turning torque is close to the specified range.
G Changes in turning torque of final drive assembly per
revolution should be within 1.0 N-m (10 kg-cm, 8.7 in-lb)
without binding.
6. Calculate dimension O (thickness of adjusting shim) using the
following procedure to satisfy specification of end play for input
shaft rear bearing.
Use the "Available Shims" table for the available shim sizes. Refer to MT-65, "Available Adjusting Shims" .
a. Using block gauge, scale, and dial gauge, measure dimension
O1 between transaxle case end face and mounting face of
adjusting shim.
SMT738DA
Turning torque of
final drive assembly
(New bearing)
: 2.9 - 6.9 N-m (30 - 70 kg-cm,
26 - 61 in-lb)
SMT600-E
End play : 0 - 0.06 mm (0 - 0.0024 in)
Dimension O = (O1 O2) + End play
O : Thickness of adjusting shim
O1 : Distance between transaxle case
end face and mounting face of
adjusting shim
O2 : Distance between clutch housing
case end face and end face of
input shaft rear bearing
SMT743D
SMT744D
TRANSAXLE ASSEMBLY
MT-37
[RS5F70A]
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b. Using block gauge, scale, and dial gauge as shown in the figure,
measure dimension O2 between clutch housing case end face
and end face of input shaft rear bearing.
7. Install selected input shaft rear bearing adjusting shim onto input shaft.
8. Install oil gutter into transaxle case.
9. Clean mating surfaces of clutch housing and transaxle case.
Check for cracks and damage, then apply sealant. Use Genuine
Anaerobic Liquid Gasket or equivalent. Refer to GI-44, "Recom-
mended Chemical Products and Sealants" .
10. Install transaxle case onto clutch housing, and tighten mounting
bolts with specified torque.
SMT745D
SMT650D
SMT802D
Transaxle case mounting
bolts
: Refer to MT-20, "CASE
COMPONENTS" .
SMT649D
MT-38
[RS5F70A]
TRANSAXLE ASSEMBLY
11. Apply sealant to threads of back-up lamp switch, PNP switch,
and drain plug, then install them. Use Genuine Anaerobic Liquid
Gasket or equivalent. Refer to GI-44, "Recommended Chemical
Products and Sealants" .
NOTE:
Fill the case with oil before installation of filler plug.
12. Install speedometer pinion assembly.
CAUTION:
Do not reuse O-ring.
13. Install check springs and check balls. Apply sealant to the
thread on the check plug, and install it.
14. Calculate thickness of adjusting shim using the following proce-
dure to satisfy specification of end play for mainshaft rear bear-
ing.
Use the "Available Shims" table for the available shim sizes. Refer to MT-65, "Available Adjusting Shims" .
a. Using dial gauge as shown in the figure, measure dimension
P1 between transaxle case end face and mainshaft rear bear-
ing.
WMT023
SMT749D
End play : 0 - 0.06 mm (0 - 0.0024 in)
Dimension P = (P1 P2) + End play
P : Thickness of adjusting shim
P1 : Distance between transaxle case
end face and mainshaft rear bearing
P2 : Distance between adjusting shim
end face of rear cover and transaxle
mounting face
SMT746D
SMT747D
TRANSAXLE ASSEMBLY
MT-39
[RS5F70A]
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b. Using dial gauge as shown in the figure, measure dimension
P2 between adjusting shim mounting face of rear cover and
transaxle mounting face.
15. Using snap ring pliers and flat-head screwdriver as shown,
install snap ring.
CAUTION:
Do not reuse snap ring.
16. Install selected mainshaft adjusting shim.
17. Install reverse idler gear, O-ring, thrust washers (front and rear),
and bearing onto reverse idler shaft.
18. Install snap ring into transaxle case using snap ring pliers.
CAUTION:
G Do not reuse snap ring.
G Do not reuse O-ring.
G Before installation, apply gear oil to O-ring.
19. Using feeler gauge, measure the end play of snap ring, and
select a snap ring suitable to satisfy the following specification.
Use the "Available Shims" table for the available shim sizes.
Refer to MT-64, "Available Snap Rings" .
SMT748D
SMT646D
SMT753DA
End play : 0.05 - 0.25 mm (0.0020 - 0.0098 in)
SMT754D
MT-40
[RS5F70A]
TRANSAXLE ASSEMBLY
20. Install selected snap ring with a suitable tool.
CAUTION:
Do not reuse snap ring.
21. Apply gear oil to rear cover O-ring, and install rear cover, side cover gasket, and side cover. Then tighten
mounting bolts with specified torque.
Use the "Available Shims" table for the available shim sizes. Refer to MT-20, "CASE COMPONENTS" .
CAUTION:
Do not reuse mounting bolts for rear cover and side cover.
SMT644D
INPUT SHAFT AND GEARS
MT-41
[RS5F70A]
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INPUT SHAFT AND GEARS PFP:32200
Disassembly ECS005TQ
1. Before disassembly, measure the end plays of 3rd and 4th input
gears with a suitable tool. Refer to MT-64, "Gear End Play" .
G If end play is not within specification, disassemble and check
the parts.
2. Remove oil channel from input shaft rear bearing.
3. Press out input shaft rear bearing using Tool.
4. Remove C-ring holder.
5. Remove 5th gear rear C-ring.
SMT759D
SMT671D
SMT672DA
SMT673D
MT-42
[RS5F70A]
6. Remove 5th input gear from input shaft using Tool.
7. Remove 5th gear front C-ring.
8. Remove 4th input gear, baulk ring, 4th gear needle bearing, and
4th gear C-ring from input shaft.
9. Press out both 3rd & 4th synchronizer hub assembly and 3rd
input gear from input shaft using Tool.
10. Remove 3rd gear needle bearing.
11. Press out input shaft front bearing from input shaft using Tool.
Inspection ECS005TR
GEAR AND SHAFT
G Check shaft for cracks, wear or bending.
G Check gears for excessive wear, chips or cracks.
SMT674DA
SMT675DA
SMT676DA
SMT693D
MT-43
[RS5F70A]
D
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MT
SYNCHRONIZERS
G Check spline area of coupling sleeves, hubs and gears for wear
or cracks.
G Check baulk rings for cracks or deformation.
G Check insert springs for wear or deformation.
G If any crack, damage, or excessive wear is found on cam face of
baulk ring or working face of insert, replace it.
G Measure the movement (free play in dimension L) of 3rd & 4th
coupling sleeve with the end fixed and the other end lifted as
shown in the figure. If the movement exceeds specification,
replace the sleeve.
G Measure clearance between baulk ring and gear. Refer to MT-
64, "Clearance Between Baulk Ring and Gear" .
SMT637A
SMT867D
Coupling sleeve Dimension L
3rd & 4th 0 - 0.95 mm (0 - 0.0374 in)
SMT841D
SMT140
MT-44
[RS5F70A]
BEARING
G Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.
Assembly ECS005TS
1. Press on input shaft front bearing using Tool.
2. Install 3rd gear needle, 3rd input gear and 3rd gear baulk ring bearing to input shaft.
3. Install spread spring, shifting insert, and 3rd & 4th synchronizer
hub onto 3rd & 4th coupling sleeve.
G Pay attention to the shape of spread spring and shifting insert
for correct assembly.
Do not install spread spring hook onto the same shifting
insert.
CAUTION:
Do not reuse 3rd & 4th synchronizer hub.
G Install synchronizer hub with its three grooves facing the front
side (3rd input gear side).
SMT148A
SMT696DA
SMT694D
SMT695D
MT-45
[RS5F70A]
D
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G Install 3rd & 4th coupling sleeve with its chamfered surface
facing the 4th input gear side.
4. Position bearing replacer to the front side of input shaft front
bearing.
G Align grooves of shifting insert and 3rd gear baulk ring. Then,
press it onto 3rd & 4th synchronizer hub assembly using a
drift.
5. Install 4th gear C-ring onto input shaft using Tool.
6. Measure the end play of 3rd & 4th synchronizer hub with a suit-
able tool, and check if it is within allowable specification.
7. If not within specification, adjust the end play by changing thick-
ness of 4th (input) gear C-ring. Refer to MT-64, "Available C-
rings" .
8. Install 4th gear needle bearing, 4th gear baulk ring, and 5th gear
front C-ring.
9. Install 4th input gear using Tool.
SMT699D
SMT698DA
End play : 0 - 0.06 mm (0 - 0.0024 in)
SMT700D
SMT701DA
MT-46
[RS5F70A]
10. Position 5th input gear as shown, to install it on input shaft.
11. Install 5th input gear using Tool as shown.
CAUTION:
Do not reuse 5th input gear.
12. Install 5th gear rear C-ring onto input shaft using Tool.
13. Measure the end play of 5th input gear with a suitable tool, and
check if it is within the allowable specification below.
14. If not within specification, adjust the end play by changing thickness of the 5th (input gear) rear C-ring.
Refer to MT-64, "Available C-rings" .
15. Install C-ring holder onto 5th gear rear C-ring using Tool.
CAUTION:
Do not reuse C-ring holder.
16. Install input shaft rear bearing using Tool.
CAUTION:
Install input shaft rear bearing with its brown surface facing
the input gear side.
SMT703D
SMT702DA
End play : 0 - 0.06 mm (0 - 0.0024 in)
SMT704D
SMT705DA
MT-47
[RS5F70A]
D
E
F
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M
A
B
MT
17. Install oil channel onto input shaft.
18. Measure gear end play as a final check. Refer to MT-64, "Gear End Play" .
SMT671D
MT-48
[RS5F70A]
MAINSHAFT AND GEARS
MAINSHAFT AND GEARS PFP:32241
Disassembly ECS005TT
1. Before disassembly, measure gear end play with a suitable tool.
Refer to MT-64, "Gear End Play" .
G If end play is not within the specified limit, disassemble and
check the parts.
2. Remove snap ring with a suitable tool.
3. Remove C-ring holder and mainshaft C-ring.
4. Press out mainshaft rear bearing from mainshaft using Tool.
SMT760D
SMT677D
SMT678D
SMT679DA
MAINSHAFT AND GEARS
MT-49
[RS5F70A]
D
E
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M
A
B
MT
5. Remove mainshaft thrust washer.
6. Remove snap ring from mainshaft. Then, remove reverse main gear assembly, reverse gear needle bear-
ing, and reverse gear baulk ring.
7. Place bearing replacer between 5th & reverse synchronizer hub
and 5th main gear, and press out both reverse gear bushing and
5th & reverse synchronizer assembly using Tool.
8. Remove 5th main gear, 5th gear baulk ring, and 5th gear needle bearing.
9. Place bearing replacer between 3rd and 4th main gears, and
press out both 5th gear bushing and 4th main gear using Tool.
10. Remove mainshaft adjusting shim and spacer.
11. Place bearing replacer between 2nd main gear and 1st & 2nd synchronizer hub, and press out both 3rd
and 2nd main gears.
12. Remove 2nd double cone assembly, 2nd gear bushing, and coupling sleeve assembly.
SMT680D
WMT024
WMT025
SMT683D
MT-50
[RS5F70A]
MAINSHAFT AND GEARS
13. Place bearing replacer on 1st gear front side, and press out all
of 2nd gear bushing, 1st & 2nd synchronizer hub, 1st main gear,
and 1st double cone using Tool.
14. Remove 1st gear needle bearing.
Inspection ECS005TU
GEAR AND SHAFT
G Check shaft for cracks, wear or bending.
G Check gears for excessive wear, chips or cracks.
SYNCHRONIZERS
G Check spline area of coupling sleeves, hubs and gears for wear
or cracks.
G Check baulk rings for cracks or deformation.
G Check insert springs for wear or deformation.
WMT026
SMT693D
SMT637A
SMT867D
MAINSHAFT AND GEARS
MT-51
[RS5F70A]
D
E
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M
A
B
MT
G Measure the movement (play, dimension L) of 1st & 2nd cou-
pling sleeve and 5th & reverse coupling sleeve with their end
fixed and the other end lifted as shown in the figure. If the move-
ment exceeds specification, replace the sleeve.
G Measure clearance between baulk ring and gear. Refer to MT-
64, "Clearance Between Baulk Ring and Gear" .
BEARING
pitting or wear.
G Measure wear of inner and outer baulk ring as shown.
Place baulk rings in position on synchronizer cone.
While holding baulk ring against synchronizer cone as far as it will go, measure dimensions A and B
using Tool.
G If dimension A or B is smaller than the wear limit, replace outer baulk ring, inner baulk ring
and synchronizer cone as a set.
Coupling sleeve Length L
1st & 2nd 0 - 0.68 mm (0 - 0.0268 in)
5th & Reverse 0 - 0.89 mm (0 - 0.0350 in)
SMT868D
SMT140
SMT148A
Standard "A": 0.6 - 0.8 mm (0.024 - 0.031 in)
"B": 0.6 - 1.1 mm (0.024 - 0.043 in)
Wear limit : 0.2 mm (0.008 in)
WMT017
MT-52
[RS5F70A]
MAINSHAFT AND GEARS
Assembly ECS005TV
1. Install 1st gear needle bearing and 1st main gear onto main-
shaft.
2. Install 1st double cone assembly onto mainshaft.
3. Install 1st & 2nd synchronizer hub with its three grooves facing
the front side (1st main gear side) onto mainshaft.
CAUTION:
Do not reuse 1st & 2nd synchronizer hub.
4. Install 1st & 2nd synchronizer hub using Tool.
5. Install insert spring onto 1st & 2nd coupling sleeve.
SMT706D
SMT695D
SMT707DA
SMT994BB
MAINSHAFT AND GEARS
MT-53
[RS5F70A]
D
E
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M
A
B
MT
6. Install 1st & 2nd coupling sleeve with its chamfered surface fac-
ing the 1st main gear side onto 1st & 2nd synchronizer hub.
7. Install 2nd gear bushing with its flange surface facing 1st & 2nd
synchronizer hub side using Tool.
8. Install 2nd needle bearing, 2nd double cone assembly, and 2nd
main gear onto mainshaft using Tool.
9. Position 3rd main gear as shown, and install it using Tool.
CAUTION:
Do not reuse 3rd main gear.
10. Install spacer and mainshaft adjusting shim onto mainshaft.
11. Select a mainshaft adjusting shim suitable to satisfy the follow-
ing specification of dimension L and install it onto mainshaft.
SMT708D
WMT027
SMT710DA
Specification of
dimension L
: 151.35 - 151.45 mm
(5.9586 - 5.9626 in)
Mainshaft adjusting
shims
: Refer to MT-65, "Available
Adjusting Shims" .
SMT711D
MT-54
[RS5F70A]
MAINSHAFT AND GEARS
12. Position 4th main gear as shown, and install it onto mainshaft.
13. Install 4th main gear onto mainshaft using Tool.
CAUTION:
Do not reuse 4th main gear.
14. Install 5th gear bushing with its flange surface facing the 4th
main gear side using Tool.
15. Install 5th needle bearing, 5th main gear, and 5th gear baulk ring
onto mainshaft.
16. Being careful of the following points, install spread spring, shift-
ing insert, and 5th & reverse synchronizer hub onto 5th &
reverse coupling sleeve.
SMT713D
SMT712DA
WMT028
SMT761D
SMT694D
MAINSHAFT AND GEARS
MT-55
[RS5F70A]
D
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A
B
MT
G Pay attention to the shape of spread spring and shifting insert
for correct assembly.
Do not install spread spring hook onto the same shifting
insert.
G Install synchronizer hub with its three grooves facing the front
side (5th main gear side).
CAUTION:
Do not reuse 5th & reverse synchronizer hub.
G Install 5th & reverse coupling sleeve with its chamfered sur-
face facing the reverse main gear side.
17. Install 5th & reverse synchronizer hub assembly using Tool.
18. Install reverse gear baulk ring using Tool.
19. Install reverse gear bushing using Tool.
20. Install reverse gear needle bearing using Tool.
21. Install sub-gear, sub-gear washer, and snap ring onto reverse
main gear.
CAUTION:
G Pay attention to direction of sub-gear washer.
G Do not reuse snap ring.
SMT695D
SMT716D
SMT715DA
WMT029
SMT718D
MT-56
[RS5F70A]
MAINSHAFT AND GEARS
22. Install reverse main gear assembly onto mainshaft.
23. Select a thrust washer suitable to satisfy the following specifica-
tion of dimension M as shown, and install it onto mainshaft.
24. Install mainshaft rear bearing using Tool.
25. Install mainshaft C-ring.
26. Using feeler gauge, measure the end play of mainshaft rear
bearing with a suitable tool, and check if it satisfies the following
specification.
27. Install C-ring holder.
Specification of
dimension M
: 244.20 - 244.30 mm
(9.6142 - 9.6181 in)
Available thrust
washers
: Refer to MT-67, "Avail-
able Thrust Washer" .
SMT719D
SMT720DA
End play : 0 - 0.06 mm (0 - 0.0024 in)
Mainshaft C-rings : Refer to MT-64, "Available C-
rings" .
SMT721D
SMT678D
MAINSHAFT AND GEARS
MT-57
[RS5F70A]
D
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A
B
MT
28. Install snap ring with a suitable tool.
29. Measure gear end play as a final check. Refer to MT-64, "Gear End Play" .
SMT677D
MT-58
[RS5F70A]
FINAL DRIVE
FINAL DRIVE PFP:38411
Pre-inspection ECS005TW
DIFFERENTIAL CASE SIDE
1. Clean final drive assembly sufficiently to prevent side gear thrust washer, differential case, side gear, and
other parts from sticking by gear oil.
2. Upright the differential case so that the side gear to be mea-
sured faces upward.
3. Place final drive adapter and dial gauge onto side gear. Move
side gear up and down, and measure the clearance using Tool.
4. If not within specification, adjust the clearance by changing thrust washer thickness.
5. Turn differential case upside down, and measure the clearance between side gear and differential case on
the other side in the same way using Tool.
Disassembly ECS005TX
1. Remove the final gear bolts. Then, separate the final gear from
differential case.
2. Make a notch and remove speedometer drive gear using a
scraper or other suitable tool.
G Bearing replacer cannot be positioned unless speedome-
ter drive gear is removed.
3. Remove differential side bearing of final gear side using Tool.
4. Turn differential case upside down, and remove differential side
bearing of speedometer drive gear side using Tool.
G Be careful not to mix up the differential side bearings.
5. Remove speedometer stopper.
6. Remove lock pins from pinion mate shaft using Tool.
Clearance between side gear and
differential case
: 0.1 - 0.2 mm
(0.004 - 0.008 in)
SMT685DA
SMT609A
WCIA0005E
SMT689DA
FINAL DRIVE
MT-59
[RS5F70A]
D
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A
B
MT
7. Remove pinion mate shaft.
8. Rotate pinion mate gear, and remove pinion mate gear, pinion
mate thrust washer, side gear, and side gear thrust washer from
differential case.
Inspection ECS005TY
GEAR, WASHER, SHAFT AND CASE
G Check mating surfaces of differential case, side gears and pin-
ion mate gears.
G Check washers for wear.
BEARING
pitting or wear.
CAUTION:
When replacing tapered roller bearing, replace outer and
inner race as a set.
Assembly ECS005TZ
1. Apply gear oil to sliding area of differential case, each gear, and
thrust washer.
2. Install side gear thrust washer and side gear into differential
case.
3. Position pinion mate gear and pinion mate thrust washer diago-
nally, and install them into differential case while rotating.
SMT839
WCIA0004E
SPD715
SMT062A
MT-60
[RS5F70A]
FINAL DRIVE
4. Insert pinion mate shaft into differential case.
5. Upright the differential case so that its side gear to be measured
faces upward.
6. Place preload adapter and dial gauge onto side gear. Move side
gear up and down, and measure the clearance using Tool.
7. Turn differential case upside down, and measure the clearance
between side gear and differential case on the other side in the
same way using Tool.
8. Install retaining pin using Tool.
G Make sure that retaining pin is flush with case.
9. Align and install speedometer drive gear into differential case.
10. Install speedometer stopper.
SMT087A
Clearance of side
gear and differential
case
: 0.1 - 0.2 mm (0.004 - 0.008 in)
Differential side gear
thrust washers
: Refer to MT-67, "Available
Washers" .
SMT685DA
SMT699B
SMT842D
FINAL DRIVE
MT-61
[RS5F70A]
D
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A
B
MT
11. Install differential side bearing using Tool.
12. Turn differential case upside down, and install another differen-
tial side bearing on the other side in the same way using Tool.
13. Install the final gear into the differential case. Apply sealant onto
the final gear bolts, and tighten them in the order as shown to
the specified torque.
SMT751DA
Final gear bolts : Refer to MT-23, "FINAL DRIVE
COMPONENTS" .
SMT752D
MT-62
[RS5F70A]
SHIFT CONTROL
SHIFT CONTROL PFP:32982
Inspection ECS005U0
G Check if the width of shift fork hook (sliding area with coupling
sleeve) is within allowable specification below.
G Check if shift check groove of fork rod or 5th & reverse check
groove is worn, or has any other abnormalities.
Item
One-side wear specifi-
cation
Sliding width of new part
1st & 2nd 0.2 mm (0.008 in)
7.80 - 7.93 mm
(0.3071 - 0.3122 in)
3rd & 4th 0.2 mm (0.008 in)
7.80 - 7.93 mm
(0.3071 - 0.3122 in)
5th & reverse 0.2 mm (0.008 in)
7.80 - 7.93 mm
(0.3071 - 0.3122 in) SMT801D
SMT692D
SERVICE DATA AND SPECIFICATIONS (SDS)
MT-63
[RS5F70A]
D
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A
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MT
SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030
General Specifications ECS005U1
TRANSAXLE
*1: Refer to MA-13, "Fluids and Lubricants" .
FINAL GEAR
Engine QG18DE
Transaxle model RS5F70A
Number of speeds 5
Synchromesh type Warner
Shift pattern
Gear ratio 1st 3.333
2nd 1.955
3rd 1.286
4th 0.926
5th 0.756
Reverse 3.214
Number of teeth Input gear 1st 15
2nd 22
3rd 28
4th 41
5th 45
Rev. 14
Main gear 1st 50
2nd 43
3rd 36
4th 38
5th 34
Rev. 45
Reverse idler gear 37
Oil level (Reference) mm (in)*1 75.5 - 80.5 (2.972 - 3.169)
Oil capacity (qt) 3.0 (3 1/8)
Remarks 1st & 2nd double baulk ring type synchronizer
Reverse sub-gear
Engine QG18DE
Final gear ratio 4.176
Number of teeth
Final gear/Pinion 71/17
Side gear/Pinion mate gear 16/10
MT-64
[RS5F70A]
Gear End Play ECS005U2
Unit: mm (in)
Clearance Between Baulk Ring and Gear ECS005U3
3RD, 4TH, 5TH, REVERSE BAULK RING
Unit: mm (in)
1ST AND 2ND BAULK RING
Unit: mm (in)
Available Snap Rings ECS005U4
SNAP RING
*: Always check with the parts department for the latest information.
Available C-rings ECS005U5
4TH INPUT GEAR C-RING
Gear End play
1st main gear
0.18 - 0.31 (0.0071 - 0.0122)
2nd main gear
5th main gear
Reverse main gear
3rd input gear
4th input gear 0.17 - 0.44 (0.0067 - 0.0173)
Standard Wear limit
3rd
0.90 - 1.45 (0.0354 - 0.0571)
0.7 (0.028)
4th
5th
Reverse 0.9 - 1.35 (0.0354 - 0.0531)
Dimension Standard Wear limit
A 0.6 - 0.8 (0.024 - 0.031)
0.2 (0.008)
B 0.6 - 1.1 (0.024 - 0.043)
SMT906D
End play 0.05 - 0.25 mm (0.0020 - 0.0098 in)
Thickness Part number*
1.45 mm (0.0571 in) 32204-6J000
1.55 mm (0.0610 in) 32204-6J001
1.65 mm (0.0650 in) 32204-6J002
1.75 mm (0.0689 in) 32204-6J003
1.85 mm (0.0728 in) 32204-6J004
End play 0 - 0.06 mm (0 - 0.0024 in)
MT-65
[RS5F70A]
D
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A
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MT
5TH INPUT GEAR REAR C-RING
MAINSHAFT C-RING
Available Adjusting Shims ECS005U6
INPUT SHAFT REAR BEARING ADJUSTING SHIM
3.00 mm (0.1181 in) 32205-6J000
3.03 mm (0.1193 in) 32205-6J001
3.06 mm (0.1205 in) 32205-6J002
3.09 mm (0.1217 in) 32205-6J003
3.12 mm (0.1228 in) 32205-6J004
End play 0 - 0.06 mm (0 - 0.0024 in)
2.59 mm (0.1020 in) 32205-6J005
2.62 mm (0.1031 in) 32205-6J006
2.65 mm (0.1043 in) 32205-6J007
2.68 mm (0.1055 in) 32205-6J008
2.71 mm (0.1067 in) 32205-6J009
2.74 mm (0.1079 in) 32205-6J010
End play 0 - 0.06 mm (0 - 0.0024 in)
3.48 mm (0.1370 in) 32348-6J000
3.51 mm (0.1382 in) 32348-6J001
3.54 mm (0.1394 in) 32348-6J002
3.57 mm (0.1406 in) 32348-6J003
3.60 mm (0.1417 in) 32348-6J004
3.63 mm (0.1429 in) 32348-6J005
3.66 mm (0.1441 in) 32348-6J006
3.69 mm (0.1453 in) 32348-6J007
3.72 mm (0.1465 in) 32348-6J008
3.75 mm (0.1476 in) 32348-6J009
3.78 mm (0.1488 in) 32348-6J010
3.81 mm (0.1500 in) 32348-6J011
3.84 mm (0.1512 in) 32348-6J012
3.87 mm (0.1524 in) 32348-6J013
3.90 mm (0.1535 in) 32348-6J014
3.93 mm (0.1547 in) 32348-6J015
3.96 mm (0.1559 in) 32348-6J016
End play 0 - 0.06 mm (0 - 0.0024 in)
0.74 mm (0.0291 in) 32225-6J003
0.78 mm (0.0307 in) 32225-6J004
0.82 mm (0.0323 in) 32225-6J005
0.86 mm (0.0339 in) 32225-6J006
MT-66
[RS5F70A]
MAINSHAFT ADJUSTING SHIM
MAINSHAFT REAR BEARING ADJUSTING SHIM
0.90 mm (0.0354 in) 32225-6J007
0.94 mm (0.0370 in) 32225-6J008
0.98 mm (0.0386 in) 32225-6J009
1.02 mm (0.0402 in) 32225-6J010
1.06 mm (0.0417 in) 32225-6J011
1.10 mm (0.0433 in) 32225-6J012
1.14 mm (0.0449 in) 32225-6J013
1.18 mm (0.0465 in) 32225-6J014
1.22 mm (0.0480 in) 32225-6J015
1.26 mm (0.0496 in) 32225-6J016
1.30 mm (0.0512 in) 32225-6J017
1.34 mm (0.0528 in) 32225-6J018
1.38 mm (0.0543 in) 32225-6J019
1.42 mm (0.0559 in) 32225-6J020
1.46 mm (0.0575 in) 32225-6J021
1.50 mm (0.0591 in) 32225-6J022
1.54 mm (0.0606 in) 32225-6J023
1.58 mm (0.0622 in) 32225-6J024
1.62 mm (0.0638 in) 32225-6J060
1.66 mm (0.0654 in) 32225-6J061
Standard length L 151.35 - 151.45 mm (5.9586 - 5.9626 in)
0.48 mm (0.0189 in) 32238-6J000
0.56 mm (0.0220 in) 32238-6J001
0.64 mm (0.0252 in) 32238-6J002
0.72 mm (0.0283 in) 32238-6J003
0.80 mm (0.0315 in) 32238-6J004
0.88 mm (0.0346 in) 32238-6J005
SMT907D
End play 0 - 0.06 mm (0 - 0.0024 in)
2.99 mm (0.1177 in) 32238-6J010
3.03 mm (0.1193 in) 32238-6J011
MT-67
[RS5F70A]
D
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MT
Available Thrust Washer ECS005U7
MAINSHAFT THRUST WASHER
Available Washers ECS005U8
3.07 mm (0.1209 in) 32238-6J012
3.11 mm (0.1224 in) 32238-6J013
3.15 mm (0.1240 in) 32238-6J014
3.19 mm (0.1256 in) 32238-6J015
3.23 mm (0.1272 in) 32238-6J016
3.27 mm (0.1287 in) 32238-6J017
3.31 mm (0.1303 in) 32238-6J018
3.35 mm (0.1319 in) 32238-6J019
3.39 mm (0.1335 in) 32238-6J020
3.43 mm (0.1350 in) 32238-6J021
3.47 mm (0.1366 in) 32238-6J022
3.51 mm (0.1382 in) 32238-6J023
Standard length M 244.20 - 244.30 mm (9.6142 - 9.6181 in)
6.04 mm (0.2378 in) 32246-6J000
6.12 mm (0.2409 in) 32246-6J001
6.20 mm (0.2441 in) 32246-6J002
6.28 mm (0.2472 in) 32246-6J003
6.36 mm (0.2504 in) 32246-6J004
SMT843D
Clearance between side gear and differential case 0.1 - 0.2 mm (0.004 - 0.008 in)
Thickness mm (in) Part number*
0.75 - 0.80 (0.0295 - 0.0315) 38424-D2111
0.80 - 0.85 (0.0315 - 0.0335) 38424-D2112
0.85 - 0.90 (0.0335 - 0.0354) 38424-D2113
0.90 - 0.95 (0.0354 - 0.0374) 38424-D2114
0.95 - 1.00 (0.0374 - 0.0394) 38424-D2115
MT-68
[RS5F70A]
Available Shims Differential Side Bearing Preload and Adjusting Shim ECS005U9
BEARING PRELOAD
Unit: mm (in)
* Install shims which are deflection of differential case + T in thickness.
DIFFERENTIAL SIDE BEARING ADJUSTING SHIMS
Differential side bearing preload: T* 0.15 - 0.21 (0.0059 - 0.0083)
0.44 (0.0173) 38454-M8000
0.48 (0.0189) 38454-M8001
0.52 (0.0205) 38454-M8002
0.56 (0.0220) 38454-M8003
0.60 (0.0236) 38454-M8004
0.64 (0.0252) 38454-M8005
0.68 (0.0268) 38454-M8006
0.72 (0.0283) 38454-M8007
0.76 (0.0299) 38454-M8008
0.80 (0.0315) 38454-M8009
0.84 (0.0331) 38454-M8010
0.88 (0.0346) 38454-M8011
PRECAUTIONS
MT-69
[RS5F51A]
D
E
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MT
Cautions ECS005UA
G Check oil level or replace oil with vehicle on level ground.
G During removal or installation, keep inside of transaxle clear of dust or dirt.
G Check for the correct installation status prior to removal or disassembly. If mating marks are required, be
certain they do not interfere with the function of the parts they are applied to.
G In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, observe it.
G Be careful not to damage sliding surfaces and mating surfaces.
MT-70
[RS5F51A]
PREPARATION
Special Service Tools ECS005UB
The actual shapes of the Kent-Moore tools may differ from those of the special tools illustrated here.
Tool number
(Kent-Moore No.)
Tool name
Description
KV381054S0
(J34286)
Puller
Side bearing outer race removal
Main shaft front bearing removal
ST35321000
( )
Drift
Input shaft oil seal installation
Reverse main gear installation
1st bushing installation
1st-2nd synchronizer hub installation
2nd bushing installation
3rd main gear installation
a: 49 mm (1.93 in) dia.
b: 41 mm 1.61 in) dia.
ST30720000
(J25405)
Drift
Differential oil seal installation
Differential side bearing outer race installation
Mainshaft rear bearing installation
Differential side bearing installation
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
ST33200000
(J26082)
Drift
Mainshaft front bearing installation
4th main gear installation
a: 60 mm (2.36 in) dia.
b: 44.5 mm (1.752 in) dia.
ST33061000
(J8107-2)
Drift
Bore plug installation
Differential side bearing removal
a: 38 mm (1.50 in) dia.
b: 28.5 mm (1.122 in) dia.
ST33052000
( )
Drift
Welch plug installation
Input shaft rear bearing removal
Input shaft bearing spacer and 5th stopper re-
moval
5th bushing, thrust washer, 4th input gear, 4th
gear bushing, 3rd-4th synchronizer hub and
3rd input gear removal
Input shaft front bearing installation
Mainshaft rear bearing removal
4th main gear and 5th main gear removal
a: 22 mm (0.87 in) dia.
b: 28 mm (1.10 in) dia.
ZZA0601D
ZZA1000D
ZZA0811D
ZZA1002D
ZZA1000D
ZZA1023D
PREPARATION
MT-71
[RS5F51A]
D
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MT
KV40105020
( )
Drift
5th input gear and synchronizer hub removal
3rd main gear, 2nd main gear, 2nd bushing,
1st-2nd synchronizer hub, 1st main gear, re-
verse main gear and 1st bushing removal
a: 39.7 mm (1.563 in) dia.
b: 35 mm (1.38 in) dia.
c: 15 mm (0.59 in).
KV40105710
( )
Press stand
3rd-4th synchronizer hub installation
4th bushing installation
5th synchronizer hub installation
a: 46 mm (1.81 in) dia.
b: 41 mm (1.61 in).
ST38220000
( )
Press stand
a: 63 mm (2.48 in) dia.
b: 65 mm (2.56 in).
ST30032000
(J26010-01)
Drift
5th stopper and input shaft bearing spacer in-
stallation
a: 63 mm (2.48 in) dia.
b: 38 mm (1.50 in) dia.
c: 31 mm (1.22 in) dia.
ST30901000
(J26010-01)
Drift
Input shaft rear bearing installation
a: 79 mm (3.11 in) dia.
b: 45 mm (1.77 in) dia.
c: 35.2 mm (1.386 in) dia.
ST30031000
(J22912-01)
Puller
Measuring wear of 1st and 2nd baulk ring
KV40101630
(J35870)
Drift
a: 68 mm (2.68 in) dia.
b: 60 mm (2.36 in) dia.
Tool number
(Kent-Moore No.)
Tool name
Description
ZZA1133D
ZZA1058D
ZZA1058D
ZZA0978D
ZZA0978D
ZZA0537D
ZZA1003D
MT-72
[RS5F51A]
PREPARATION
Commercial Service Tools ECS005UC
KV38102510
( )
Drift
a: 71 mm (2.80 in) dia.
b: 65 mm (2.56 in) dia.
(J39713)
Preload adapter
Checking differential side gear end play
Tool number
(Kent-Moore No.)
Tool name
Description
ZZA0838D
NT087
Puller Each bearing gear and bushing removal
Pin punch Each retaining pin removal and installation
Tip: 4.5 mm (0.177 in) dia.
ZZB0823D
NT077
ZZA0815D
MT-73
[RS5F51A]
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NVH Troubleshooting Chart ECS005UD
Reference page
M
T
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6
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6
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M
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8
8
Suspected parts (possible cause)
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Symptom
Noise 1 2 3 3
MT-74
[RS5F51A]
DESCRIPTION
Cross-sectional View ECS005UE
LCIA0032E
DESCRIPTION
MT-75
[RS5F51A]
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MT
Double-cone synchronizer is adopted for 1st and 2nd gears to
reduce operating force of the shift lever.
REVERSE GEAR
Description of reverse gear components are as shown.
SCIA0750E
SCIA0751E
MT-76
[RS5F51A]
M/T OIL
M/T OIL PFP:KLD20
Replacement ECS005UF
DRAINING
1. Start the engine and let it run to warm up the transaxle.
3. Set a new gasket on the drain plug and install it on the transaxle.
CAUTION:
FILLING
2. After refilling oil, check oil level. Assemble new gasket on to filler plug, then install it on the transaxle body.
CAUTION:
Checking ECS005UG
CAUTION:
G Set a new gasket on the filler plug and install it on the transaxle.
CAUTION:
Drain plug : 30 - 39 Nm (3.1 - 4.0 kg-m, 23 - 28 ft-lb)
Filler plug : 30 - 39 Nm (3.1 - 4.0 kg-m, 23 - 28 ft-lb)
WCIA0022E
SIDE OIL SEAL
MT-77
[RS5F51A]
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Removal and Installation ECS005UH
REMOVAL
1. Remove the drive shaft from the transaxle body. Refer to FAX-14, "Removal" .
2. Remove oil seal with a slotted screwdriver.
CAUTION:
Be careful not to damage the case surface when removing
the oil seal.
INSTALLATION
G Using Tool (drift), drive the oil seal straight until it protrudes from
the case end equal to dimension "A" as shown.
Special Service Tool
CAUTION:
G When installing oil seal, apply multi-purpose grease to oil seal lips.
G Oil seal is not reusable.
G Check the oil level after installation. Refer to MT-76, "Checking" .
WCIA0023E
Dimension "A" : Within 0.5 mm (0.02 in) or flush with
the case.
SCIA1010E
Drift to be used ST30720000
MT-78
[RS5F51A]
POSITION SWITCH
Checking ECS005UI
NOTE:
For removal and installation of the switches. Refer to MT-84, "Component Parts" .
BACK-UP LAMP SWITCH
G Check continuity.
PARK/NEUTRAL POSITION SWITCH
G Check continuity.
Reverse Yes
Except reverse No
SCIA0708E
Neutral Yes
Except neutral No
CONTROL LINKAGE
MT-79
[RS5F51A]
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Removal and Installation of Control Device and Cable ECS005UJ
1. Snap pin 2. Washer 3. Cable
4. Manual lever 5. Shift cable 6. Lock plate
7. Control device assembly 8. Lock plate 9. Select cable
10. Shift cable 11. Control lever knob 12. Control lever
WCIA0136E
MT-80
[RS5F51A]
CONTROL LINKAGE
CAUTION:
G Note that the select side lock plate for securing the control cable is different from the one on the
shift side.
G After assembly, make sure selector lever automatically returns to Neutral when it is moved to 1st,
2nd, or Reverse.
Cable Adjustment ECS0077V
NOTE:
After installation of the select cable, the cable must be adjusted for proper operation. This adjustment is per-
formed before installing the interior console and shift boot.
1. Slide clip B from under clip A as shown.
2. Shift the control lever to the neutral position.
CAUTION:
Do not move the control lever when adjusting the cables.
3. Push clip A into the cable end case until it snaps into place as
shown.
4. Slide clip B back over clip A until it snaps into place and holds
clip A in place as shown.
13. Control device assembly 14. Cover 15. Select cable
16. Floor 17. Pin 18. Shift cable
19. Washer 20. Clutch housing 21. Cable mounting bracket
22. Select cable 23. Shift cable 24. Lock plate
25. Lock plate
LCIA0303E
LCIA0304E
LCIA0305E
AIR BREATHER HOSE
MT-81
[RS5F51A]
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AIR BREATHER HOSE PFP:31098
Removal and Installation ECS005UK
Refer to the illustration for air breather hose removal and installation information.
CAUTION:
G Make sure there are no pinched or restricted areas on the air breather hose caused by bending or
winding when installing it.
G Be sure to insert hose into the transaxle tube until overlap area reaches the spool.
LCIA0033E
MT-82
[RS5F51A]
TRANSAXLE ASSEMBLY
Removal and Installation ECS005UL
REMOVAL
1. Remove air cleaner and air duct.
2. Remove battery.
3. Remove the air breather hose. Refer to MT-81, "Removal and Installation" .
4. Remove clutch operating cylinder.
CAUTION:
Do not depress clutch pedal during removal procedure.
5. Remove engine under cover.
6. Remove the control cable from the transaxle. Refer to MT-79, "Removal and Installation of Control Device
and Cable" .
7. Drain gear oil from transaxle. Refer to MT-76, "Replacement" .
8. Disconnect connectors and harnesses for:
G PNP switch.
G Speed sensor.
G Back-up lamp switch.
G Ground.
9. Remove the exhaust front tube. Refer to EX-3, "Removal and Installation" .
10. Remove the drive shafts. Refer to FAX-14, "Removal" .
11. Remove starter motor. Refer to SC-20, "Removal and Installation" .
12. Place a jack under the transaxle.
CAUTION:
When setting the jack, be careful not to bring it into contact with the switch.
13. Remove the center member, the engine insulator and the engine mount bracket.
WCIA0109E
TRANSAXLE ASSEMBLY
MT-83
[RS5F51A]
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14. Support the engine by placing a jack under the oil pan. Do not position the jack so it is in contact with the
drain plug.
15. Remove the bolts that mount the engine to the transaxle.
16. Remove the transaxle from the vehicle.
INSTALLATION
Installation is the reverse order of removal.
G When installing the transaxle to the engine, use the tightening torque and sequence shown below:
CAUTION:
When installing transaxle, be careful not to bring transaxle input shaft into contact with the clutch
cover.
G After installation, check oil level, and look for leaks and loose
mechanisms.
MTD0062D
Bolt No. 1 2 3 4 5 6 7 8 9 10
mm (in) 40 82 47 47 52 40 40 40 30 30
Tightening
torque
Nm (kg-m,
ft-lb)
30 - 40
(3.1 - 4.1,
22 - 29)
70 - 80 (7.1 - 8.1, 52 - 59) 30 - 40 (3.1 - 4.1, 22 - 29)
LCIA0036E
MT-84
[RS5F51A]
TRANSAXLE ASSEMBLY
Component Parts ECS005UM
CASE AND HOUSING COMPONENTS
1. Clutch housing 2. Input shaft oil seal 3. Oil channel
4. Magnet 5. Differential oil seal 6. Ball pin
7. Washer 8. Transaxle case 9. Welch plug
10. Bore plug 11. Differential oil seal 12. Park/Neutral position switch
13. Oil gutter 14. Back-up lamp switch 15. Air breather tube
16. Baffle plate 17. Filler plug 18. Gasket
19. Drain plug 20. Gasket
SCIA1062E
TRANSAXLE ASSEMBLY
MT-85
[RS5F51A]
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MT
GEAR COMPONENTS
1. Input shaft front bearing 2. Input shaft 3. Needle bearing
4. 3rd input gear 5. 3rd baulk ring 6. Spread spring
7. 3rd & 4th shifting insert 8. 3rd & 4th synchronizer hub 9. 4th baulk ring
10. 3rd & 4th coupling sleeve 11. Bushing 12. Needle bearing
13. 4th input gear 14. Thrust washer 15. Bushing
16. Needle bearing 17. 5th input gear 18. 5th baulk ring
19. 5th shifting insert 20. 5th synchronizer hub 21. 5th coupling sleeve
22. 5th stopper 23. Input shaft bearing spacer 24. Snap ring
25. Input shaft rear bearing 26. Oil channel 27. Input shaft rear bearing adjusting
shim
28. Lock pin 29. Reverse idler shaft 30. Thrust needle bearing
31. Needle bearing 32. Reverse idler gear (front) 33. Reverse baulk ring
34. Reverse coupling sleeve 35. Insert spring 36. Reverse idler gear (rear)
37. Reverse idler gear adjusting shim
SCIA0385E
MT-86
[RS5F51A]
TRANSAXLE ASSEMBLY
1. Mainshaft front bearing 2. Mainshaft bearing retainer 3. Mainshaft
4. Reverse main gear 5. 1st main gear 6. Bushing
7. Needle bearing 8. 1st inner baulk ring 9. 1st gear synchronizer cone
10. 1st outer baulk ring 11. Spread spring 12. 1st & 2nd shifting insert
13. 1st & 2nd synchronizer hub 14. 2nd outer baulk ring 15. 2nd gear synchronizer cone
16. 2nd inner baulk ring 17. 1st & 2nd coupling sleeve 18. Bushing
19. Needle bearing 20. 2nd main gear 21. 3rd main gear
22. 3rd & 4th mainshaft spacer 23. 4th main adjusting shim 24. 4th main gear
25. 5th main gear 26. Snap ring 27. Mainshaft rear bearing
31. Snap ring 32. Mainshaft rear bearing adjusting shim
SCIA0386E
TRANSAXLE ASSEMBLY
MT-87
[RS5F51A]
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1. Reverse shift fork 2. Shifter cap 3. Reverse fork rod
4. Reverse lever assembly 5. 5th & reverse bracket 6. 5th & reverse fork rod
7. 5th shift fork 8. Retaining pin 9. 3rd & 4th bracket
10. 3rd & 4th shift fork 11. 3rd & 4th fork rod 12. 1st & 2nd shift fork
13. 1st & 2nd bracket 14. 1st & 2nd fork rod 15. Shift check sleeve
16. Inter lock pin 17. Check ball 18. Shift check sleeve
19. Check spring 20. Check plug 21. Control rod assembly
22. O-ring 23. Shift check 24. Stopper bolt
25. Stopper ring
SCIA0387E
MT-88
[RS5F51A]
TRANSAXLE ASSEMBLY
Disassembly and Assembly ECS005UN
DISASSEMBLY
1. Remove drain plug and filler plug.
2. Remove park/neutral position switch and back-up lamp switch.
3. After removing shift check and stopper bolt, remove control
assembly.
1. Differential side bearing outer race 2. Differential side bearing 3. Speedometer drive gear
4. Differential case 5. Final gear 6. Differential side bearing
7. Differential side bearing outer race 8. Differential side bearing adjusting shim 9. Pinion mate shaft
10. Side gear 11. Side gear thrust washer 12. Pinion mate gear
13. Pinion mate gear washer 14. Retaining pin
WCIA0208E
SCIA0389E
TRANSAXLE ASSEMBLY
MT-89
[RS5F51A]
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4. Remove check plugs (3 pieces), check springs (3 pieces), check
balls (3 pieces) and shift check sleeve (1 piece) as shown.
5. Remove transaxle case fixing bolts as shown.
6. Remove bore plug.
CAUTION:
Be careful not to damage transaxle case.
7. While spreading the snap ring of mainshaft rear bearing located at bore plug hole, remove transaxle case.
8. Remove oil gutter, baffle plate.
9. Remove snap ring, mainshaft rear bearing adjusting shim and input shaft rear bearing adjusting shim from
transaxle case.
10. Remove differential side bearing outer race (transaxle case
side) and the adjustment shim using Tool as shown.
11. Remove the welch plug as shown.
SCIA0396E
SCIA0983E
SCIA1021E
SCIA0402E
MT-90
[RS5F51A]
TRANSAXLE ASSEMBLY
12. Remove differential oil seal as shown.
13. Remove magnet from clutch housing.
14. With shift lever in 5th position, remove the bracket bolts from the
reverse lever assembly. Lift the reverse lever assembly to
remove.
CAUTION:
Be careful not to lose shifter cap.
15. Pull out reverse fork rod then remove reverse shift fork.
16. Shift 3rd & 4th fork rod to 3rd position. Remove retaining pin of
5th shift fork using pin punch.
17. Remove stopper rings for 5th & reverse bracket.
18. Pull out 5th & reverse fork rod and remove 5th shift fork and 5th & reverse bracket.
19. Remove check balls (2 pieces) and inter lock pin.
SCIA0397E
SCIA0390E
SCIA0391E
SCIA0392E
TRANSAXLE ASSEMBLY
MT-91
[RS5F51A]
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20. Remove retaining pin of 3rd & 4th bracket using pin punch.
21. Remove stopper rings for 3rd & 4th shift fork.
22. Pull out 3rd & 4th fork rod and remove 3rd & 4th shift fork and bracket.
23. Remove shift check sleeve from clutch housing.
24. Remove retaining pin of 1st & 2nd shift fork using pin punch.
25. Pull out 1st & 2nd shift fork with bracket.
26. Remove 1st & 2nd shift fork.
27. Remove retaining pin of 1st & 2nd bracket using pin punch and separate 1st & 2nd fork rod and bracket.
28. Remove gear components from clutch housing.
a. While tapping input shaft with plastic hammer, remove input
shaft assembly, mainshaft assembly and reverse idler gear
assembly as a set.
CAUTION:
Always withdraw mainshaft straight out. Failure to do so
can damage resin oil channel on clutch housing side.
b. Remove final drive assembly.
29. Remove mainshaft bearing retainer and then the mainshaft front
bearing using Tool as shown.
30. Remove oil channel on mainshaft side.
31. Remove differential oil seal (clutch housing side).
SCIA0393E
SCIA0394E
SCIA0395E
SMT117E
MT-92
[RS5F51A]
TRANSAXLE ASSEMBLY
32. Remove differential side bearing outer race (clutch housing
side).
33. Remove input shaft oil seal.
CAUTION:
Be careful not to damage clutch housing.
ASSEMBLY
1. Install a new input shaft oil seal from the clutch housing end, to a
depth of 1.8 - 2.8 mm (0.071 - 0.110 in) using Tool as shown.
CAUTION:
Oil seals are not reusable.
2. Install a new differential oil seal using Tool as shown.
CAUTION:
SMT116E
SCIA0398E
SCIA1022E
SCIA1023E
TRANSAXLE ASSEMBLY
MT-93
[RS5F51A]
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3. Install oil channel on mainshaft side.
CAUTION:
Position oil channel with specified orientation for installa-
tion as shown.
4. Install mainshaft front bearing using Tool as shown.
CAUTION:
Install with orientation as shown.
5. Install bearing retainer for mainshaft front bearing.
CAUTION:
Install with the punched surface facing up.
6. Install differential side bearing outer race using Tool as shown.
7. Install final drive assembly into clutch housing.
SCIA0986E
SCIA1024E
Bearing retainer bolt : 6.27 - 8.33 Nm (0.64 - 0.84 kg-m,
56 - 73 in-lb)
SCIA0400E
SCIA1063E
SCIA0888E
MT-94
[RS5F51A]
TRANSAXLE ASSEMBLY
8. Install input shaft assembly, mainshaft assembly, and reverse
idler gear assembly into clutch housing.
CAUTION:
Be sure not to damage input shaft oil seal.
9. Install 1st-2nd fork rod bracket onto 1st-2nd fork rod, and then
install a new retaining pin.
CAUTION:
Retaining pins are not reusable.
10. Install 1st-2nd fork rod and 1st-2nd shift fork, and then install a
new retaining pin.
CAUTION:
11. Install shift check sleeve.
12. Install 3rd-4th bracket, 3rd-4th shift fork, and 3rd-4th fork rod
with interlock pin.
13. Install a new stopper ring onto 3rd-4th shift fork.
CAUTION:
Stopper rings are not reusable.
14. Install a new retaining pin onto 3rd-4th bracket.
CAUTION:
15. Install 2 check balls.
SCIA0395E
SCIA0889E
SCIA0394E
SCIA0393E
TRANSAXLE ASSEMBLY
MT-95
[RS5F51A]
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16. Install 5th-reverse bracket, 5th shift fork, and 5th-reverse fork
rod.
17. Install a new stopper ring onto 5th-reverse bracket.
CAUTION:
18. Install a new retaining pin onto 5th shift fork.
CAUTION:
19. Install reverse shift fork and reverse fork rod.
20. Install reverse lever assembly following procedures below.
a. Install shifter cap onto reverse lever assembly cam, and then install them onto reverse shift fork.
CAUTION:
Do not drop shifter cap.
b. While lifting reverse shift fork, align cam with 5th-reverse fork
rod bracket.
c. Install the reverse lever assembly and tighten the reverse lever
assembly bolts to specification.
21. Install the magnet onto clutch housing.
22. Install selected input shaft adjusting shim onto input shaft.
G For selection of adjusting shims, refer to MT-98, "INPUTSHAFT END PLAY" .
23. Install baffle plate and oil gutter.
24. Install transaxle case following procedures below.
SCIA0392E
SCIA0391E
SCIA0890E
Reverse lever
assembly bolts
: 11.8 - 15.6 Nm (1.2 - 1.5 kg-m,
9 - 11 ft-lb)
SCIA0390E
MT-96
[RS5F51A]
TRANSAXLE ASSEMBLY
a. Install selected mainshaft rear bearing adjusting shim into transaxle case.
G For selection of adjusting shims, refer to MT-100, "MAINSHAFT END PLAY" .
b. Temporarily install a new snap ring for the mainshaft rear bearing into transaxle case.
CAUTION:
Do not reuse the snap ring.
c. Apply sealant to mating surfaces of transaxle case and clutch
housing. Use Genuine Anaerobic Liquid Gasket or equivalent.
Refer to GI-44, "Recommended Chemical Products and Seal-
ants" .
CAUTION:
Remove old sealant adhering to mounting surfaces. Also
remove any moisture, oil, or foreign material adhering to
application and mounting surfaces.
d. With snap ring of mainshaft rear bearing temporarily installed,
place transaxle case over clutch housing as shown.
e. Through bore plug mounting hole, with snap ring stretched, and lift up mainshaft assembly from the con-
trol assembly mounting hole.
f. Securely install snap ring onto mainshaft rear bearing as shown.
SCIA0891E
SCIA0892E
SCIA0893E
TRANSAXLE ASSEMBLY
MT-97
[RS5F51A]
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MT
g. Tighten mounting bolts "A" and "B" to specification as shown.
CAUTION:
Always replace bolts "B" as they are self-sealing bolts.
h. Install control assembly.
CAUTION:
Do not reuse the O-ring.
i. Install a new shift check and a new stopper bolt.
CAUTION:
Shift check and stopper bolt are not reusable.
25. Install a new bore plug using Tool as shown.
CAUTION:
Bore plugs are not reusable.
26. Install a new welch plug using Tool as shown.
CAUTION:
Do not reuse the welch plug.
27. Install 1 shift check sleeve, 3 check balls, 3 check springs, and 3
new check ball plugs as shown.
CAUTION:
Check ball plugs are not reusable.
Bolt A : 50.0 - 53.9 Nm (5.1 - 5.4 kg-m, 37 - 39 ft-lb)
Bolt B : 63.0 - 66.9 Nm (6.5 - 6.8 kg-m, 47 - 49 ft-lb)
SCIA1064E
SCIA1025E
SMT131E
SCIA0396E
MT-98
[RS5F51A]
TRANSAXLE ASSEMBLY
28. Apply sealant to threads of PNP switch and back-up lamp
switch, then install them into transaxle case. Use Genuine
Anaerobic Liquid Gasket or equivalent. Refer to GI-44, "Recom-
mended Chemical Products and Sealants" .
29. Install new gaskets onto drain plug and filler plug, and then
install them into transaxle case.
CAUTION:
G Gaskets are not reusable.
G After oil is filled, tighten filler plug to specified torque.
Adjustment ECS005UO
INPUTSHAFT END PLAY
G When adjusting input shaft end play, select adjusting shim for
input shaft bearing. To select adjusting shim, measure clearance
between transaxle case and input shaft rear bearing.
G Calculate dimension "O" (thickness of adjusting shim) using the
following procedure to meet specification of end play for input
shaft rear bearing.
Adjusting Shim
CAUTION:
Only 1 adjusting shim can be selected.
1. Using depth micrometer and straight edge, measure dimension
"O1 " between transaxle case end face and mounting face of
adjusting shim as shown.
SCIA0895E
End play : 0 - 0.06 mm (0 - 0.0024 in)
Dimension O = (O1 - O2 ) + End play
O : Thickness of adjusting shim
O1 : Distance between transaxle case end face
and mounting face of adjusting shim
O2 : Distance between clutch housing case end
face and end face of input shaft rear bearing
SCIA1006E
Shim thickness Part number Shim thickness Part number Shim thickness Part number
0.40 mm (0.0157 in)
0.44 mm (0.0173 in)
0.48 mm (0.0189 in)
0.52 mm (0.0205 in)
0.56 mm (0.0220 in)
0.60 mm (0.0236 in)
0.64 mm (0.0252 in)
0.68 mm (0.0268 in)
0.72 mm (0.0283 in)
0.76 mm (0.0299 in)
0.80 mm (0.0315 in)
0.84 mm (0.0331 in)
32225 8H500
32225 8H501
32225 8H502
32225 8H503
32225 8H504
32225 8H505
32225 8H506
32225 8H507
32225 8H508
32225 8H509
32225 8H510
32225 8H511
0.88 mm (0.0346 in)
0.92 mm (0.0362 in)
0.96 mm (0.0378 in)
1.00 mm (0.0396 in)
1.04 mm (0.0409 in)
1.08 mm (0.0425 in)
1.12 mm (0.0441 in)
1.16 mm (0.0457 in)
1.20 mm (0.0472 in)
1.24 mm (0.0488 in)
1.28 mm (0.0504 in)
1.32 mm (0.0520 in)
32225 8H512
32225 8H513
32225 8H514
32225 8H515
32225 8H516
32225 8H517
32225 8H518
32225 8H519
32225 8H520
32225 8H521
32225 8H522
32225 8H523
1.36 mm (0.0520 in)
1.40 mm (0.0551 in)
1.44 mm (0.0567 in)
1.48 mm (0.0583 in)
1.52 mm (0.0598 in)
1.56 mm (0.0614 in)
1.60 mm (0.0630 in)
1.64 mm (0.0646 in)
1.68 mm (0.0661 in)
1.72 mm (0.0677 in)
32225 8H524
32225 8H560
32225 8H561
32225 8H562
32225 8H563
32225 8H564
32225 8H565
32225 8H566
32225 8H567
32225 8H568
SCIA1002E
TRANSAXLE ASSEMBLY
MT-99
[RS5F51A]
D
E
F
G
H
I
J
K
L
M
A
B
MT
"O2 " between clutch housing case end face and end face of
input shaft rear bearing as shown.
3. Install selected input shaft rear bearing adjusting shim onto input shaft.
DIFFERENTIAL SIDE BEARING PRELOAD
G When adjusting differential side bearing preload, select adjust-
ing shim for differential side bearing. To select adjusting shim,
measure clearance L between transaxle case and differential
side bearing outer race.
G Calculate dimension L (thickness of adjusting shim) using the
following procedure to meet specification of preload for differen-
tial side bearing.
Adjusting Shim
CAUTION:
Up to 2 adjusting shims can be selected.
"L1 " between clutch housing case end face and mounting face
of adjusting shim as shown.
SCIA1004E
Preload : 0.15 - 0.21 mm (0.0059 - 0.0083 in)
Dimension L = (L1 - L2 ) + Preload
L : Thickness of adjusting shim
L1 : Distance between clutch housing case end
face and mounting face of adjusting shim
L2 : Distance between differential side bearing
and transaxle case
SCIA0896E
Shim thickness Part number
0.48 mm (0.0189 in)
0.52 mm (0.0205 in)
0.56 mm (0.0220 in)
0.60 mm (0.0236 in)
0.64 mm (0.0252 in)
0.68 mm (0.0268 in)
0.72 mm (0.0283 in)
0.76 mm (0.0299 in)
0.80 mm (0.0315 in)
0.84 mm (0.0331 in)
0.88 mm (0.0346 in)
0.92 mm (0.0362 in)
31438 80X00
31438 80X01
31438 80X02
31438 80X03
31438 80X04
31438 80X05
31438 80X06
31438 80X07
31438 80X08
31438 80X09
31438 80X10
31438 80X11
SCIA1078E
MT-100
[RS5F51A]
TRANSAXLE ASSEMBLY
2. Install outer race onto differential side bearing on final gear side. Holding the outer race horizontally by
hand, rotate final gear five times or more (for smooth movement of bearing roller).
"L2 " between differential side bearing outer race and transaxle
case end face as shown.
4. Install selected adjusting shim and then differential side bearing
outer race using Tool as shown.
MAINSHAFT END PLAY
G When adjusting mainshaft end play, select adjusting shim for
mainshaft rear bearing. To select adjusting shim, measure clear-
ance M between transaxle case and mainshaft rear bearing.
G Calculate dimension "P" (thickness of adjusting shim) using the
following procedure to meet specification of end play for main-
shaft rear bearing.
SCIA1079E
SCIA1026E
End play : 0 - 0.06 mm (0 - 0.0024 in)
Dimension P = "M" + End play
P : Thickness of adjusting shim
M : Distance between mainshaft rear bearing and
transaxle case
SCIA0904E
TRANSAXLE ASSEMBLY
MT-101
[RS5F51A]
D
E
F
G
H
I
J
K
L
M
A
B
MT
Adjusting Shim
CAUTION:
1. Install mainshaft assembly to clutch housing.
2. Install snap ring to transaxle case.
3. Install transaxle case to clutch housing, and temporarily assemble them with fixing bolts. Install snap ring
temporarily to mainshaft rear bearing.
4. Install dial gauge to snap ring access hole, and expand snap
ring. Lift mainshaft assembly through control assembly installa-
tion hole, and push it against transaxle case. This state shall be
defined as base. Moving distance of mainshaft assembly, with
snap ring fit on main bearing, becomes M.
REVERSE IDLER GEAR END PLAY
G When adjusting reverse idler gear end play, select adjusting shim for reverse idler gear. To select adjust-
ing shim, measure clearance between transaxle case and reverse idler gear.
G Calculate dimension "Q" (thickness of adjusting shim) using the
following procedure to meet specification of end play for reverse
idler gear.
0.44 mm (0.0173 in)
0.48 mm (0.0189 in)
0.52 mm (0.0205 in)
0.56 mm (0.0220 in)
0.60 mm (0.0236 in)
0.64 mm (0.0252 in)
0.68 mm (0.0268 in)
0.72 mm (0.0283 in)
0.76 mm (0.0299 in)
0.80 mm (0.0315 in)
0.84 mm (0.0331 in)
0.88 mm (0.0346 in)
0.92 mm (0.0362 in)
0.96 mm (0.0378 in)
1.00 mm (0.0396 in)
1.04 mm (0.0409 in)
1.08 mm (0.0425 in)
32238 8H510
32238 8H511
32238 8H512
32238 8H513
32238 8H514
32238 8H515
32238 8H516
32238 8H517
32238 8H518
32238 8H519
32238 8H520
32238 8H521
32238 8H522
32238 8H523
32238 8H524
32238 8H560
32238 8H561
SCIA1017E
End play : 0.04 - 0.14 mm (0.0016 - 0.0055 in)
Dimension Q = (Q1 - Q2 ) + End play
Q : Thickness of adjusting shim
Q1 : Distance between transaxle case end face
Q2 : Distance between clutch housing case end
face and end face of reverse idler gear
SCIA1007E
MT-102
[RS5F51A]
TRANSAXLE ASSEMBLY
Adjusting Shim
CAUTION:
"Q1 " between transaxle case end face and mounting face of
adjusting shim as shown.
"Q2 " between clutch housing case end face and end face of
reverse idler gear as shown.
3. Install selected reverse idler gear adjusting shim onto reverse idler gear.
1.76 mm (0.0693 in)
1.84 mm (0.0724 in)
1.92 mm (0.0756 in)
2.00 mm (0.0787 in)
2.08 mm (0.0819 in)
2.16 mm (0.0850 in)
2.24 mm (0.0882 in)
2.32 mm (0.0913 in)
2.40 mm (0.0945 in)
2.48 mm (0.0976 in)
2.56 mm (0.1008 in)
2.64 mm (0.1039 in)
32237 8H500
32237 8H501
32237 8H502
32237 8H503
32237 8H504
32237 8H505
32237 8H506
32237 8H507
32237 8H508
32237 8H509
32237 8H510
32237 8H511
SCIA1003E
SCIA1005E
MT-103
[RS5F51A]
D
E
F
G
H
I
J
K
L
M
A
B
MT
Disassembly and Assembly ECS005UP
DISASSEMBLY
1. Before disassembling, measure the end play for 3rd, 4th, and
5th input gears as shown.
CAUTION:
If measurement is outside the standard range, disassemble
to check contact surfaces of gear, shaft, and hub. Adjust
with snap ring at assembly.
2. Remove the oil channel.
3. Remove the input shaft rear bearing using Tool as shown.
4. Remove the snap ring as shown.
5. Remove input shaft bearing spacer and 5th stopper simulta-
neously using Tool as shown.
End play standard range
3rd gear : 0.18 - 0.31 mm (0.0071 - 0.0122 in)
4th gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)
5th gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
SCIA0914E
SCIA1027E
SCIA0916E
SCIA1028E
MT-104
[RS5F51A]
6. Remove 5th input gear and synchronizer hub assembly simulta-
7. Remove 5th needle bearing.
8. Remove 5th bushing, thrust washer, 4th input gear, 4th needle
bearing, 4th bushing, 4th baulk ring, 3rd-4th synchronizer hub
assembly, 3rd baulk ring and 3rd input gear simultaneously
using Tool as shown.
9. Remove 3rd needle bearing.
10. Remove input shaft front bearing using Tool as shown.
INSPECTION AFTER DISASSEMBLY
Input Shaft and Gears
Check parts for conditions listed below. If necessary, replace them
with new ones.
G Damage, peeling, dent, uneven wear, bending of shaft.
G Excessive wear, damage, peeling of gears.
SMT137E
SCIA1030E
SCIA0920E
LCIA0306E
MT-105
[RS5F51A]
D
E
F
G
H
I
J
K
L
M
A
B
MT
Synchronizer
with new ones.
G Damage and excessive wear of contact surfaces of coupling
sleeve, synchronizer hub, and shifting insert
G Coupling sleeve and synchronizer hub must move smoothly.
Baulk Ring Clearance
with new ones.
G Press baulk ring against cone, and measure clearance between
baulk ring and cone. If measurement is below limit, replace it
with a new one.
Bearing
with new ones.
G Damage and rough rotation of bearing
ASSEMBLY
1. Install 3rd needle bearing.
2. Install 3rd input gear and 3rd baulk ring.
SMT387A
SMT867D
Baulk ring clearance
Standard
3rd and 4th : 0.9 - 1.45 mm (0.035 - 0.0571 in)
5th : 0.95 - 1.4 mm (0.0374 - 0.055 in)
Limit value : 0.7 mm (0.028 in)
SMT140
MTF0041D
MT-106
[RS5F51A]
3. Install spread spring, shifting insert and new 3rd-4th synchro-
nizer hub onto 3rd-4th coupling sleeve.
CAUTION:
G Install with orientation of synchronizer hub as shown.
G Do not reuse 3rd-4th synchronizer hub.
G Install with orientation of coupling sleeve as shown.
G Do not to hook the ends of the two spread springs (front
and back have two each) on the same shifting insert as
shown.
4. Install 3rd-4th synchronizer hub assembly using Tool as shown.
CAUTION:
Align the grooves of the shifting insert and 3rd baulk ring.
5. Install 4th bushing using Tool as shown.
6. Install 4th baulk ring.
7. Install 4th input gear and 4th needle bearing.
SCIA0921E
SCIA0993E
SCIA1083E
SCIA1031E
SCIA1032E
MT-107
[RS5F51A]
D
E
F
G
H
I
J
K
L
M
A
B
MT
8. Select thrust washer so that dimension C2 satisfies standard
below. Then install it onto input shaft.
CAUTION:
Only one thrust washer can be selected.
Thrust Washer
9. Install 5th bushing using Tool as shown.
10. Install 5th needle bearing and 5th input gear.
11. Install 5th baulk ring.
12. Install spread spring, shifting insert and 5th synchronizer hub onto 5th coupling sleeve.
CAUTION:
G Install with orientation of synchronizer hub and shifting
insert as shown.
Standard for dimension C2 : 154.7 - 154.8 mm
(6.091 - 6.094 in)
SCIA0925E
Thickness Part number Thickness Part number
3.84 mm (0.1512 in)
3.90 mm (0.1535 in)
3.96 mm (0.1559 in)
32347 8H500
32347 8H501
32347 8H502
4.02 mm (0.1583 in)
4.08 mm (0.1606 in)
4.14 mm (0.1630 in)
32347 8H503
32347 8H504
32347 8H505
SCIA1033E
SCIA0927E
MT-108
[RS5F51A]
G Do not hook the ends of the two spread springs (front
and back has two each) on the same shifting insert as
shown.
13. Install 5th synchronizer hub assembly using Tool as shown.
CAUTION:
Align the grooves of 5th shifting insert and 5th baulk ring.
14. Install 5th stopper and then input shaft bearing spacer using
Tool as shown.
15. Install snap ring onto input shaft, and check that end play (gap
between snap ring and groove) of input shaft bearing spacer is
within the standard value.
G If the measurement is outside the standard value, select the
required snap ring size to correct the end play.
SCIA0994E
SCIA1083E
SCIA1039E
SCIA1034E
End play standard value : 0 - 0.1 mm (0 - 0.004 in)
SCIA0930E
MT-109
[RS5F51A]
D
E
F
G
H
I
J
K
L
M
A
B
MT
Snap Rings
16. Install the input shaft rear bearing using Tool as shown.
CAUTION:
17. Install the input shaft front bearing using Tool as shown.
18. Install the oil channel onto input shaft.
19. Check the end play of 3rd, 4th, and 5th input gears.
1.71 mm (0.0673 in)
1.76 mm (0.0693 in)
1.81 mm (0.0713 in)
1.86 mm (0.0732 in)
1.91 mm (0.0752 in)
1.96 mm (0.0772 in)
32204 8H510
32204 8H511
32204 8H512
32204 8H513
32204 8H514
32204 8H515
2.01 mm (0.0791 in)
2.06 mm (0.0811 in)
2.11 mm (0.0831 in)
2.16 mm (0.0850 in)
2.21 mm (0.0871 in)
2.26 mm (0.0890 in)
32204 8H516
32204 8H517
32204 8H518
32204 8H519
32204 8H520
32204 8H521
SCIA1035E
SCIA1036E
End play standard value
3rd gear : 0.18 - 0.31 mm (0.0071 - 0.0122 in)
4th gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)
5th gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
SCIA0914E
MT-110
[RS5F51A]
MAINSHAFT AND GEARS
Disassembly and Assembly ECS005UQ
DISASSEMBLY
1. Before disassembling, measure the end play of 1st and 2nd
main gears.
CAUTION:
If the measurement is outside the standard value, disas-
semble to check the contact surfaces of the gear, shaft, and
hub. Adjust with the correct snap ring size at assembly.
2. Remove the snap ring.
3. Remove the C-ring holder, and then mainshaft C-ring as shown.
4. Remove the mainshaft rear bearing using Tool as shown.
1st gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)
2nd gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
SCIA0933E
SCIA0934E
SCIA1043E
SCIA0936E
MAINSHAFT AND GEARS
MT-111
[RS5F51A]
D
E
F
G
H
I
J
K
L
M
A
B
MT
6. Remove 4th main gear and 5th main gear simultaneously using
Tool as shown.
7. Remove adjusting shim.
8. Remove 3rd-4th mainshaft spacer.
9. Remove 3rd main gear, 2nd main gear, 2nd needle bearing, 2nd
bushing, 1st-2nd synchronizer hub assembly, 1st main gear,
reverse main gear, 1st needle bearing, and 1st bushing simulta-
Mainshaft and Gears
Check parts listed. If necessary, replace them with new ones.
G Damage, peeling, dent, uneven wear, bending, and other non-
standard conditions of the shaft.
G Excessive wear, damage, peeling, and other non-standard con-
ditions of the gears.
Synchronizer
G Damage and unusual wear on contact surfaces of coupling
sleeve, synchronizer hub, and shifting insert.
SCIA1044E
SCIA1045E
LCIA0307E
SMT387A
MT-112
[RS5F51A]
MAINSHAFT AND GEARS
Checking the double cone synchronizer (1st and 2nd).
G Check the clearance of the outer baulk ring, synchronizer cone,
and inner baulk ring of 1st and 2nd double cone synchronizers,
following the procedure below.
NOTE:
The mean value is the middle value of a set of measurements
between the highest and lowest values. It is calculated by add-
ing the highest and lowest measured value and dividing their
sum by two: [(high value) + (low value)] / 2 = mean value.
CAUTION:
Outer baulk ring, synchronizer cone, and inner baulk ring
act as a set to control the clearances A and B. If the
measurement exceeds the service limit value, replace all of them as a set.
1. Using a dial gauge and Tool, measure clearance A at two or
more points diagonally opposite, and calculate the mean value.
2. Using a feeler gauge, measure clearance B at two or more
points diagonally opposite, and calculate the mean value.
SMT867D
SMT138E
Clearance A
Standard : 0.6 - 0.8 mm (0.024 - 0.031 in)
Limit value : 0.2 mm (0.008 in) or less
SCIA1046E
Clearance B
Standard : 0.6 - 1.1 mm (0.024 - 0.043 in)
SCIA1084E
MAINSHAFT AND GEARS
MT-113
[RS5F51A]
D
E
F
G
H
I
J
K
L
M
A
B
MT
Bearing
Check items below. If necessary, replace them with new ones.
G Damage and rough rotation of bearing
ASSEMBLY
1. Install reverse main gear using Tools as shown.
CAUTION:
Install the reverse main gear with the specified orientation
as shown.
2. Install 1st bushing using Tools as shown.
3. Install needle bearing, and then 1st main gear.
MTF0041D
SCIA1048E
SCIA0992E
SCIA1049E
MT-114
[RS5F51A]
MAINSHAFT AND GEARS
4. Install spread spring, shifting insert and new 1st-2nd synchro-
nizer hub onto 1st-2nd coupling sleeve.
CAUTION:
G Install with orientation of synchronizer hub as shown.
G Do not reuse the 1st-2nd synchronizer hub.
G Do not to hook the ends of the two spread springs (front
and back have two each) on same shifting insert as
shown.
5. Install 1st gear synchronizer assembly onto mainshaft, and syn-
chronizer hub assembly onto mainshaft using Tools as shown.
CAUTION:
G Outer baulk ring, synchronizer cone, and inner baulk ring
on 2nd gear-side must have been removed.
G Install with orientation of coupling sleeve.
6. Install 2nd bushing using Tools as shown.
7. Install outer baulk ring, synchronizer cone, and inner baulk ring
on 2nd gear-side.
8. Install 2nd needle bearing and 2nd gear.
SCIA0921E
SCIA0989E
SCIA1083E
SCIA1050E
SCIA1051E
MAINSHAFT AND GEARS
MT-115
[RS5F51A]
D
E
F
G
H
I
J
K
L
M
A
B
MT
9. Install 3rd main gear using Tools as shown.
CAUTION:
Install with orientation of 3rd main gear as shown.
10. Install 3rd-4th mainshaft spacer.
11. Select a suitable adjusting shim so that the dimension C1 sat-
isfies the standard value below, and install it onto the mainshaft
as shown.
CAUTION:
Adjusting Shims
12. Install 4th main gear using Tools as shown.
CAUTION:
Install with orientation of 4th main gear as shown.
SCIA1052E
(6.844 - 6.848 in)
SCIA0944E
0.52 mm (0.0205 in)
0.60 mm (0.0236 in)
0.68 mm (0.0268 in)
0.76 mm (0.0299 in)
32238 8H500
32238 8H501
32238 8H502
32238 8H503
0.84 mm (0.0331 in)
0.92 mm (0.0362 in)
1.00 mm (0.0394 in)
1.08 mm (0.0425 in)
32238 8H504
32238 8H505
32238 8H506
32238 8H507
SCIA1053E
MT-116
[RS5F51A]
MAINSHAFT AND GEARS
13. Install 5th main gear using Tools as shown.
CAUTION:
Install with orientation of 5th main gear as shown.
14. Install snap ring onto mainshaft, and check that end play of 5th
main gear satisfies standard value as shown.
G If measurement is outside the standard value, reselect the
required size snap ring.
Snap Rings
15. Install mainshaft rear bearing using Tools as shown.
16. Install C-ring onto mainshaft, and check that end play of main-
shaft rear bearing meets specification as shown.
G If measurement is outside the standard value, reselect the
required size C-ring.
SCIA1054E
SCIA0947E
1.85 mm (0.0728 in)
1.90 mm (0.0748 in)
1.95 mm (0.0768 in)
2.00 mm (0.0787 in)
32204 8H500
32204 8H501
32204 8H502
32204 8H503
2.05 mm (0.0807 in)
2.10 mm (0.0827 in)
2.15 mm (0.0846 in)
2.20 mm (0.0866 in)
32204 8H504
32204 8H505
32204 8H506
32204 8H507
SCIA1055E
SCIA0949E
MAINSHAFT AND GEARS
MT-117
[RS5F51A]
D
E
F
G
H
I
J
K
L
M
A
B
MT
C-rings
17. Fit C-ring holder, and install snap ring as shown.
18. Check end play of 1st and 2nd main gears.
2.535 mm (0.0866 in)
2.565 mm (0.1010 in)
2.595 mm (0.1022 in)
2.625 mm (0.1033 in)
2.655 mm (0.1045 in)
2.685 mm (0.1057 in)
2.715 mm (0.1069 in)
2.745 mm (0.1081 in)
2.775 mm (0.1093 in)
2.805 mm (0.1104 in)
32348 8H800
32348 8H801
32348 8H802
32348 8H803
32348 8H804
32348 8H805
32348 8H806
32348 8H807
32348 8H808
32348 8H809
2.835 mm (0.1116 in)
2.865 mm (0.1128 in)
2.895 mm (0.1140 in)
2.925 mm (0.1152 in)
2.955 mm (0.1163 in)
2.985 mm (0.1175 in)
3.015 mm (0.1187 in)
3.045 mm (0.1199 in)
3.075 mm (0.1211 in)
32348 8H810
32348 8H811
32348 8H812
32348 8H813
32348 8H814
32348 8H815
32348 8H816
32348 8H817
32348 8H818
SCIA0934E
1st gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)
2nd gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
MT-118
[RS5F51A]
REVERSE IDLER SHAFT AND GEARS
REVERSE IDLER SHAFT AND GEARS PFP:32281
Disassembly and Assembly ECS005UR
DISASSEMBLY
1. Remove reverse idler gear adjusting shim.
2. Remove reverse idler gear (rear), reverse coupling sleeve and insert spring simultaneously.
3. Remove reverse idler gear needle bearing.
4. Remove thrust needle bearing.
5. Remove reverse baulk ring.
6. Remove reverse idler gear (front).
7. Remove reverse idler gear needle bearing.
8. Remove thrust needle bearing.
9. Pull off locking pin from reverse idler shaft.
Reverse Idler Shaft and Gears
Check parts listed below. If necessary, replace them with new ones.
standard conditions of the shaft.
ditions of the gears.
Synchronizer
sleeve, synchronizer hub, and insert spring.
SCIA0953E
SMT637A
SMT867D
MT-119
[RS5F51A]
D
E
F
G
H
I
J
K
L
M
A
B
MT
Press baulk ring against cone, and measure clearance between
baulk ring and cone. If measurement is below limit value, replace it
with a new one.
Bearing
G Damage and rough rotation of bearing.
ASSEMBLY
Assembly is in the reverse order of disassembly.
CAUTION:
G Install with orientation of insert spring as shown.
Clearance
Standard : 0.95 - 1.4 mm (0.0374 - 0.055 in)
SMT140
SCIA0954E
MT-120
[RS5F51A]
FINAL DRIVE
Disassembly and Assembly ECS005US
PRE-INSPECTION
1. Clean final drive assembly sufficiently to prevent side gear thrust washer, differential case, side gear, and
other parts from sticking by gear oil.
2. Upright the differential case so that the side gear to be measured faces upward.
3. Place final drive adapter and dial indicator onto side gear using
Tool as shown.
4. Move side gear up and down, and measure the clearance as
shown.
CAUTION:
There must be no resistance and the gears must rotate
freely.
5. If the clearance measured is not within specification, adjust the clearance by changing the thrust washer
thickness.
6. Turn the differential case upside down, and measure the clearance between the side gear and differential
case on the other side to the same specifications, adjust using a thrust washer as necessary.
DISASSEMBLY
1. Remove the final gear bolts and then separate the final gear from the differential case.
2. Remove speedometer drive gear.
3. Using Tool and puller, remove differential side bearing (clutch
housing side) as shown.
WCIA0143E
Clearance between side gear and
differential case
: 0.1 - 0.2 mm
(0.004 - 0.008 in)
SMT611A
SCIA1019E
FINAL DRIVE
MT-121
[RS5F51A]
D
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4. Using Tool and puller, remove differential side bearing (transaxle
case side) as shown.
5. Using a pin punch, pull out lock pin and pinion mate shaft as
shown.
6. Rotate pinion mate gears, and remove pinion mate gears, pinion mate thrust washers, side gears, and
side gear thrust washers from differential case.
Gear, Washer, Shaft and Case
G Check side gears, side gear thrust washers, pinion mate shaft,
pinion mate gears, pinion mate thrust washers and differential
case as shown. If necessary, replace with new parts.
Bearing
G Check for bearing damage and rough rotation as shown. If nec-
essary, replace with new parts.
CAUTION:
When replacing tapered roller bearing, replace outer and inner
races as a set.
ASSEMBLY
1. Apply gear oil to sliding area of differential case, each gear, and thrust washer.
SCIA1060E
SCIA0908E
MTK0135D
SPD715
MT-122
[RS5F51A]
FINAL DRIVE
2. Install side gear thrust washers and side gears into differential
case as shown.
3. While rotating pinion mate thrust washers and pinion mate gears, and aligning them diagonally, install
them into differential case.
4. Insert pinion mate shaft into differential case as shown.
CAUTION:
Be sure not to damage pinion mate thrust washers.
5. Measure end play of side gears, using the procedure below.
Then select side gear thrust washer.
a. Upright the differential case so that its side gear to be measured
faces upward.
b. Place final drive adapter and dial indicator onto side gears as
shown.
c. Move side gears up and down to measure end play, and select
thrust washer so that it meets specification.
CAUTION:
G There must be no resistance and the gears must rotate
freely.
G Place differential case upside down. Measure the end
play for opposite side-gears using the same procedure.
G Only one thrust washer can be selected.
Thrust washers
SMT839
MTK0132D
WCIA0143E
End play standard value : 0.1 - 0.2 mm (0.004 - 0.008 in)
SMT611A
Thickness Part number
0.75 mm (0.0295 in)
0.80 mm (0.0315 in)
0.85 mm (0.0335 in)
0.90 mm (0.0354 in)
0.95 mm (0.0374 in)
38424 81X00
38424 81X01
38424 81X02
38424 81X03
38424 81X04
FINAL DRIVE
MT-123
[RS5F51A]
D
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6. Drive a new lock pin into the pinion mate shaft using a suitable
tool as shown.
CAUTION:
Do not reuse the lock pin.
7. Install differential side bearing (transaxle case side) using Tool
as shown.
8. Align and install speedometer drive gear onto differential case
as shown.
9. Install differential side bearing (clutch housing side) using Tools
as shown.
10. Install the final gear into the differential case, and tighten the
final gear bolts to specification.
SCIA0908E
SCIA1061E
SMT842D
SCIA1018E
COMPONENTS" .
SCIA0912E
MT-124
[RS5F51A]
SHIFT CONTROL
Inspection ECS005UT
G Check the contact surfaces and sliding areas for wear, damage,
and bending as shown. Replace any parts as necessary.
SHIFT FORK
G Check that the width of the shift fork hooks (sliding area with
coupling sleeve) as shown, are within specification.
SCIA0913E
Item One-side wear specification Sliding width of new part
1st & 2nd 0.2 mm (0.008 in)
7.80 - 7.93 mm
(0.3071 - 0.3122 in)
3rd & 4th 0.2 mm (0.008 in)
7.80 - 7.93 mm
(0.3071 - 0.3122 in)
5th 0.2 mm (0.008 in)
6.10 - 6.23 mm
(0.2402 - 0.2453 in)
Reverse 0.2 mm (0.008 in)
12.80 - 12.93 mm
(0.5039 - 0.5091 in)
SMT801D
MT-125
[RS5F51A]
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General Specifications ECS005UU
TRANSAXLE
FINAL GEAR
Engine QR25DE
Model code number 8U006
Number of speed 5
Shift pattern
2nd 1.842
3rd 1.258
4th 0.947
5th 0.772
Reverse 3.002
2nd 19
3rd 31
4th 38
5th 44
Reverse 13
Main gear 1st 41
2nd 35
3rd 39
4th 36
5th 34
Reverse 38
Reverse idler gear
Front 37
Rear 38
Remarks
Reverse synchronizer Installed
Double baulk ring type synchronizer 1st & 2rd synchronizer
SCIA0821E
Engine QR25DE
Number of teeth Final gear/Pinion 62/15
Side gear/Pinion mate gear 14/10
MT-126
[RS5F51A]
Gear End Play ECS005UV
Unit: mm (in)
Clearance Between Baulk Ring and Gear ECS005UW
3RD, 4TH, 5TH & REVERSE BAULK RING
Unit: mm (in)
1ST AND 2ND DOUBLE BAULK RING
Unit: mm (in)
Available Snap Rings ECS005UX
INPUT SHAFT SPACER
*: Always check with the Parts Department for the latest parts information.
5TH MAIN GEAR
Gear End play
1st main gear 0.20 - 0.30 (0.0079 - 0.0118)
2nd main gear 0.06 - 0.16 (0.0024 - 0.0063)
3rd input gear 0.18 - 0.31 (0.0071 - 0.0122)
4th input gear 0.20 - 0.30 (0.0079 - 0.0118)
5th input gear 0.06 - 0.16 (0.0024 - 0.0063)
Standard Wear limit
3rd 0.9 - 1.45 (0.035 - 0.0571) 0.7 (0.028)
4th 0.9 - 1.45 (0.035 - 0.0571) 0.7 (0.028)
5th 0.95 - 1.4 (0.0374 - 0.055) 0.7 (0.028)
Reverse 0.95 - 1.4 (0.0374 - 0.055) 0.7 (0.028)
A 0.6 - 0.8 (0.024 - 0.031) 0.2 (0.008)
B 1.6 - 1.1 (0.024 - 0.043) 0.2 (0.008)
SMT138E
End play 0 - 0.1 mm (0 - 0.004 in)
Thickness mm (in) Part number* Thickness mm (in) Part number*
1.71 (0.0673)
1.76 (0.0693)
1.81 (0.0713)
1.86 (0.0732)
1.91 (0.0752)
1.96 (0.0772)
32204 8H510
32204 8H511
32204 8H512
32204 8H513
32204 8H514
32204 8H515
2.01 (0.0791)
2.06 (0.0811)
2.11 (0.0831)
2.16 (0.0850)
2.21 (0.0871)
2.26 (0.0890)
32204 8H516
32204 8H517
32204 8H518
32204 8H519
32204 8H520
32204 8H521
End play 0 - 0.1 mm (0 - 0.004 in)
1.85 (0.0728)
1.90 (0.0748)
1.95 (0.0768)
2.00 (0.0787)
32204 8H500
32204 8H501
32204 8H502
32204 8H503
2.05 (0.0807)
2.10 (0.0827)
2.15 (0.0846)
2.20 (0.0866)
32204 8H504
32204 8H505
32204 8H506
32204 8H507
MT-127
[RS5F51A]
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Available C-rings ECS005UY
MAINSHAFT C-RING
Available Thrust Washers ECS005UZ
INPUT SHAFT THRUST WASHER
End play 0 - 0.06 mm (0 - 0.0024 in)
2.535 (0.0866)
2.565 (0.1010)
2.595 (0.1022)
2.625 (0.1033)
2.655 (0.1045)
2.685 (0.1057)
2.715 (0.1069)
2.745 (0.1081)
2.775 (0.1093)
2.805 (0.1104)
32348 8H800
32348 8H801
32348 8H802
32348 8H803
32348 8H804
32348 8H805
32348 8H806
32348 8H807
32348 8H808
32348 8H809
2.835 (0.1116)
2.865 (0.1128)
2.895 (0.1140)
2.925 (0.1152)
2.955 (0.1163)
2.985 (0.1175)
3.015 (0.1187)
3.045 (0.1199)
3.075 (0.1211)
32348 8H810
32348 8H811
32348 8H812
32348 8H813
32348 8H814
32348 8H815
32348 8H816
32348 8H817
32348 8H818
Standard length C2 154.7 - 154.8 mm (6.091 - 6.094in)
3.84 (0.1512)
3.90 (0.1535)
3.96 (0.1559)
32347 8H500
32347 8H501
32347 8H502
4.02 (0.1583)
4.08 (0.1606)
4.14 (0.1630)
32347 8H503
32347 8H504
32347 8H505
SCIA1008E
Allowable clearance between side gear and differential case with
washer
0.1 - 0.2 mm (0.004 - 0.008 in)
0.75 (0.0295)
0.80 (0.0315)
0.85 (0.0335)
0.90 (0.0354)
0.95 (0.0374)
38424 81X00
38424 81X01
38424 81X02
38424 81X03
38424 81X04
MT-128
[RS5F51A]
Available Adjusting Shims ECS005V0
0.52 (0.0205)
0.60 (0.0236)
0.68 (0.0268)
0.76 (0.0299)
32238 8H500
32238 8H501
32238 8H502
32238 8H503
0.84 (0.0331)
0.92 (0.0362)
1.00 (0.0394)
1.08 (0.0425)
32238 8H504
32238 8H505
32238 8H506
32238 8H507
SCIA1009E
End play 0 - 0.06 mm (0 - 0.0024 in)
Thickness mm (in) Part number* Thickness mm (in) Part number* Thickness mm (in) Part number*
0.40 (0.0157)
0.44 (0.0173)
0.48 (0.0189)
0.52 (0.0205)
0.56 (0.0220)
0.60 (0.0236)
0.64 (0.0252)
6.68 (0.0268)
0.72 (0.0283)
0.76 (0.0299)
0.80 (0.0315)
0.84 (0.0331)
32225 8H500
32225 8H501
32225 8H502
32225 8H503
32225 8H504
32225 8H505
32225 8H506
32225 8H507
32225 8H508
32225 8H509
32225 8H510
32225 8H511
0.88 (0.0346)
0.92 (0.0362)
0.96 (0.0378)
1.00 (0.0396)
1.04 (0.0409)
1.08 (0.0425)
1.12 (0.0441)
1.16 (0.0457)
1.20 (0.0472)
1.24 (0.0488)
1.28 (0.0504)
1.32 (0.0520)
32225 8H512
32225 8H513
32225 8H514
32225 8H515
32225 8H516
32225 8H517
32225 8H518
32225 8H519
32225 8H520
32225 8H521
32225 8H522
32225 8H523
1.36 (0.0520)
1.40 (0.0551)
1.44 (0.0567)
1.48 (0.0583)
1.52 (0.0598)
1.56 (0.0614)
1.60 (0.0630)
1.64 (0.0646)
1.68 (0.0661)
1.72 (0.0677)
32225 8H524
32225 8H560
32225 8H561
32225 8H562
32225 8H563
32225 8H564
32225 8H565
32225 8H566
32225 8H567
32225 8H568
End play 0 - 0.06 mm (0 - 0.0024 in)
0.44 (0.0173)
0.48 (0.0189)
0.52 (0.0205)
0.56 (0.0220)
0.60 (0.0236)
0.64 (0.0252)
0.68 (0.0268)
0.72 (0.0283)
0.76 (0.0299)
32238 8H510
32238 8H511
32238 8H512
32238 8H513
32238 8H514
32238 8H515
32238 8H516
32238 8H517
32238 8H518
0.80 (0.0315)
0.84 (0.0331)
0.88 (0.0346)
0.92 (0.0362)
0.96 (0.0378)
1.00 (0.0396)
1.04 (0.0409)
1.08 (0.0425)
32238 8H519
32238 8H520
32238 8H521
32238 8H522
32238 8H523
32238 8H524
32238 8H560
32238 8H561
MT-129
[RS5F51A]
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REVERASE IDLER GEAR ADJUSTING SHIM
Available Shims ECS005V1
Differential Side Bearing Preload and Adjusting Shim
BEARING PRELOAD
*: Install shims which are deflection of differential case + L in thickness.
DIFFERENTIAL SIDE BEARING ADJUSTING SHIM(S)
End play 0.04 - 0.14 mm (0.0016 - 0.0055 in)
1.76 (0.0693)
1.84 (0.0724)
1.92 (0.0756)
2.00 (0.0787)
2.08 (0.0819)
2.16 (0.0850)
32237 8H500
32237 8H501
32237 8H502
32237 8H503
32237 8H504
32237 8H505
2.24 (0.0882)
2.32 (0.0913)
2.40 (0.0945)
2.48 (0.0976)
2.56 (0.1008)
2.64 (0.1039)
32237 8H506
32237 8H507
32237 8H508
32237 8H509
32237 8H510
32237 8H511
Differential side bearing preload: L* 0.15 - 0.21 mm (0.0059 - 0.0083)
0.48 (0.0189)
0.52 (0.0205)
0.56 (0.0220)
0.60 (0.0236)
0.64 (0.0252)
0.68 (0.0268)
31438 80X00
31438 80X01
31438 80X02
31438 80X03
31438 80X04
31438 80X05
0.72 (0.0283)
0.76 (0.0299)
0.80 (0.0315)
0.84 (0.0331)
0.88 (0.0346)
0.92 (0.0362)
31438 80X06
31438 80X07
31438 80X08
31438 80X09
31438 80X10
31438 80X11
MT-130
[RS6F51H]
PRECAUTIONS
Caution ECS005V2
G Check oil level, and drain and refill transaxle oil with the vehicle on level ground.
G During removal or installation, keep inside of transaxle clean of dust and dirt.
G Check for the correct installation orientation prior to removal or disassembly. If mating marks are required,
be certain they do not interfere with the function of the parts they are applied to.
G In principle, tighten bolts or nuts gradually in several steps working diagonally and from inside to outside
as applicable. If a tightening sequence is specified, follow it as specified.
G Be careful not to damage the sliding surfaces and mating surfaces of parts.
PREPARATION
MT-131
[RS6F51H]
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Special Service Tools ECS005V3
The actual shapes of the Kent-Moore tools may differ from those of the special tools illustrated here.
Tool number
(Kent-Moore No.)
Tool name
Description
KV381054S0
(J34286)
Puller
Side bearing outer race removal
Mainshaft front bearing removal
ST35321000
( )
Drift
Input shaft oil seal installation
a: 49 mm (1.93 in) dia.
b: 41 mm (1.61 in) dia.
ST30720000
(J25405)
Drift
Differential oil seal installation
Differential side bearing outer race installation
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
ST33200000
(J26082)
Drift
Mainshaft front bearing installation
a: 60 mm (2.36 in) dia.
b: 44.5 mm (1.752 in) dia.
ST33061000
(J8107-2)
Drift
Bore plug installation
Differential side bearing removal
a: 38 mm (1.50 in) dia.
b: 28.5 mm (1.122 in) dia.
ST33052000
( )
Drift
Welch plug installation
Input shaft rear bearing removal
5th bushing, thrust washer, 4th input gear, 4th
gear bushing, 3rd-4th synchronizer hub and
3rd input gear removal
6th input gear and 6th bushing removal
Mainshaft rear bearing removal
4th main gear and 5th main gear removal
6th main gear removal
a: 22 mm (0.87 in) dia.
b: 28 mm (1.10 in) dia.
ZZA0601D
ZZA1000D
ZZA0811D
ZZA1002D
ZZA1000D
ZZA1023D
MT-132
[RS6F51H]
PREPARATION
KV40105020
( )
Drift
5th input gear and synchronizer hub removal
3rd main gear, 2nd main gear, 2nd bushing,
1st-2nd synchronizer hub, 1st main gear, re-
verse main gear and 1st bushing removal
a: 39.7 mm (1.563 in) dia.
b: 35 mm (1.38 in) dia.
c: 15 mm (0.59 in)
KV40105710
( )
Press stand
3rd-4th synchronizer hub installation
5th-6th synchronizer hub installation
a: 46 mm (1.81 in) dia.
b: 41 mm (1.61 in)
ST38220000
( )
Press stand
a: 63 mm (2.48 in) dia.
b: 65 mm (2.56 in)
ST30032000
(J26010-01)
Drift
a: 80 mm (3.15 in) dia.
b: 38 mm (1.50 in) dia.
c: 31 mm (1.22 in) dia.
ST30901000
(J26010-01)
Drift
Input shaft rear bearing installation
a: 79 mm (3.11 in) dia.
b: 45 mm (1.77 in) dia.
c: 35.2 mm (1.386 in) dia.
ST30031000
(J22912-01)
Puller
Measuring wear of 1st and 2nd baulk ring
Tool number
(Kent-Moore No.)
Tool name
Description
ZZA1133D
ZZA1058D
ZZA1058D
ZZA0978D
ZZA0978D
ZZA0537D
PREPARATION
MT-133
[RS6F51H]
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Commercial Service Tools ECS005V4
KV40101630
(J35870)
Drift
a: 68 mm (2.68 in) dia.
b: 60 mm (2.36 in) dia.
KV38102510
( )
Drift
a: 71 mm (2.80 in) dia.
b: 65 mm (2.56 in) dia.
Tool number
(Kent-Moore No.)
Tool name
Description
ZZA1003D
ZZA0838D
Pin punch Each retaining pin removal and installation
Tip: 4.5 mm (0.177 in) dia.
ZZB0823D
NT077
ZZA0815D
MT-134
[RS6F51H]
NVH Troubleshooting Chart ECS005V5
Reference page
M
T
-
7
6
M
T
-
7
6
M
T
-
7
6
M
T
-
8
4
M
T
-
1
4
0
M
T
-
8
7
M
T
-
8
5
,

M
T
-
8
8
Suspected parts (possible cause)
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Symptom
Noise 1 2 3 3
DESCRIPTION
MT-135
[RS6F51H]
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MT
Cross-sectional View ECS005V6
SCIA0999E
MT-136
[RS6F51H]
DESCRIPTION
Double-cone synchronizer is used for 1st and 2nd gears to reduce
operating force of the shift lever as shown.
REVERSE GEAR
Description of reverse gear components is as shown.
SCIA0750E
SCIA0751E
M/T OIL
MT-137
[RS6F51H]
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M/T OIL PFP:KLD20
Replacement ECS005V7
DRAINING
1. Start the engine and let it run to warm up the transaxle oil.
3. Set a new gasket on the drain plug and install it in transaxle body.
CAUTION:
FILLING
2. After refilling oil, check oil level. Assemble a new gasket on to filler plug, then install it in transaxle body.
CAUTION:
Checking ECS005V8
CAUTION:
G Set a new gasket on the filler plug and install it in transaxle body.
CAUTION:
Drain plug : 30 - 39 Nm (3.1 - 4.0 kg-m, 23 - 28 ft-lb)
WCIA0022E
MT-138
[RS6F51H]
SIDE OIL SEAL
Removal and Installation ECS005V9
REMOVAL
1. Remove the drive shaft from the transaxle body. Refer to FAX-14, "Removal" .
2. Remove oil seal with a slotted screwdriver.
CAUTION:
Be careful not to damage the case surface when removing
the oil seal.
INSTALLATION
G Using Tool (drift), drive the new oil seal straight until it protrudes
from the case end equal to dimension "A" as shown.
CAUTION:
G Before installing oil seal, apply multi-purpose grease to
oil seal lips.
G Oil seal is not reusable.
G Check oil level after installation. Refer to MT-137, "Checking" .
WCIA0023E
Dimension "A" : Within 0.5 mm (0.02 in) or flush with
the case.
Drift to be used (special service tool) ST30720000 (J25405)
SCIA1010E
POSITION SWITCH
MT-139
[RS6F51H]
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MT
Checking ECS005VA
NOTE:
For removal and installation of the switches. Refer to MT-145, "Component Parts" .
BACK-UP LAMP SWITCH
G Check continuity.
PARK/NEUTRAL POSITION SWITCH
G Check continuity.
Reverse Yes
Except reverse No
SCIA0708E
Neutral Yes
Except neutral No
MT-140
[RS6F51H]
CONTROL LINKAGE
Removal and Installation of Control Device and Cable ECS006H6
1. Snap pin 2. Washer 3. Cable
4. Manual lever 5. Shift cable 6. Lock plate
7. Control device assembly 8. Lock plate 9. Select cable
10. Shift cable 11. Control lever knob 12. Control lever
WCIA0136E
CONTROL LINKAGE
MT-141
[RS6F51H]
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CAUTION:
G Note that the select side lock plate for securing the control cable is different from the one on the
shift side.
G After assembly, make sure selector lever automatically returns to Neutral when it is moved to 1st,
2nd, or Reverse.
Cable Adjustment ECS0077W
NOTE:
After installation of the select cable, the cable must be adjusted for proper operation. This adjustment is per-
formed before installing the interior console and shift boot.
1. Slide clip B from under clip A as shown.
2. Shift the control lever to the neutral position.
CAUTION:
Do not move the control lever when adjusting the cables.
3. Push clip A into the cable end case until it snaps into place as
shown.
4. Slide clip B back over clip A until it snaps into place and holds
clip A in place as shown.
13. Control device assembly 14. Cover 15. Select cable
16. Floor 17. Pin 18. Shift cable
19. Washer 20. Clutch housing 21. Cable mounting bracket
22. Select cable 23. Shift cable 24. Lock plate
25. Lock plate
LCIA0303E
LCIA0304E
LCIA0305E
MT-142
[RS6F51H]
AIR BREATHER HOSE
AIR BREATHER HOSE PFP:31098
Removal and Installation ECS005VC
CAUTION:
G Make sure there are no pinched or restricted areas on the air breather hose caused by bending or
winding when installing it.
G Insert the air breather hose into the transaxle tube until the overlap area reaches the spool.
LCIA0033E
TRANSAXLE ASSEMBLY
MT-143
[RS6F51H]
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Removal and Installation ECS005VD
REMOVAL
1. Remove the air cleaner and air duct.
2. Remove the battery.
3. Remove the air breather hose. Refer to MT-81, "Removal and Installation" .
4. Remove the clutch operating cylinder.
CAUTION:
Do not depress the clutch pedal during the removal procedure.
5. Remove the engine under cover.
6. Disconnect the control cable from the transaxle. Refer to MT-140, "Removal and Installation of Control
Device and Cable" .
7. Drain the gear oil from the transaxle. Refer to MT-76, "Replacement" .
8. Remove the connectors and harnesses for:
G PNP switch
G Speed sensor
G Back-up lamp switch
G Ground
9. Remove the exhaust front tube. Refer to EX-3, "Removal and Installation" .
10. Remove the drive shaft. Refer to FAX-14, "Removal" .
11. Remove the starter motor. Refer to SC-20, "Removal and Installation" .
12. Place a suitable jack under the transaxle.
CAUTION:
When setting the jack, be careful not to bring it into contact with the switches.
13. Remove the center member, engine insulator, and engine mount bracket.
14. Support the engine by placing a jack under the engine oil pan.
WCIA0109E
MT-144
[RS6F51H]
TRANSAXLE ASSEMBLY
15. Remove the bolts that mount the engine to the transaxle.
16. Remove the transaxle from the vehicle as shown.
INSTALLATION
Installation is the reverse order of removal.
G When installing the transaxle to the engine, use them specified tightening torque in the numerical
sequence as shown.
CAUTION:
When installing the transaxle, do not allow the transaxle input shaft to make contact with the
clutch cover.
G After installation, check the transaxle oil level, and check for any
leaks and any loose mechanisms.
MTD0062D
Bolt No. 1 2 3 4 5 6 7 8 9 10
mm (in) 40 82 47 47 52 40 40 40 30 30
Tightening
torque
Nm (kg-m,
ft-lb)
30 - 40
(3.1 - 4.1,
22 - 29)
70 - 80 (7.1 - 8.1, 52 - 59) 30 - 40 (3.1 - 4.1, 22 - 29)
LCIA0036E
TRANSAXLE ASSEMBLY
MT-145
[RS6F51H]
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Component Parts ECS005VE
CASE AND HOUSING COMPONENTS
1. Clutch housing 2. Input shaft oil seal 3. Oil channel
4. Magnet 5. Differential oil seal 6. Ball pin
7. Washer 8. Transaxle case 9. Welch plug
10. Bore plug 11. Differential oil seal 12. Park/Neutral position switch
13. Oil gutter 14. Back-up lamp switch 15. Air breather tube
16. Baffle plate 17. Filler plug 18. Gasket
19. Drain plug 20. Gasket
SCIA1062E
MT-146
[RS6F51H]
TRANSAXLE ASSEMBLY
GEAR COMPONENTS
1. Input shaft front bearing 2. Input shaft 3. Needle bearing
4. 3rd input gear 5. 3rd baulk ring 6. Spread spring
7. 3rd & 4th shifting insert 8. 3rd & 4th synchronizer hub 9. 4th baulk ring
10. 3rd & 4th coupling sleeve 11. Bushing 12. Needle bearing
13. 4th input gear 14. Thrust washer 15. Bushing
16. Needle bearing 17. 5th input gear 18. 5th baulk ring
19. 5th & 6th shifting insert 20. 5th & 6th synchronizer hub 21. 5th & 6th coupling sleeve
22. Baulk ring 23. 6th input gear 24. Needle bearing
25. Bushing 26. Snap ring 27. Input shaft rear bearing
28. Oil channel 29. Input shaft rear bearing adjusting
shim
30. Retaining pin
31. Reverse idler shaft 32. Thrust bearing 33. Needle bearing
34. Reverse idler gear (Front) 35. Reverse baulk ring 36. Reverse coupling sleeve
37. Insert spring 38. Reverse idler gear (Rear) 39. Reverse idler gear adjusting shim
SCIA0956E
TRANSAXLE ASSEMBLY
MT-147
[RS6F51H]
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1. Mainshaft front bearing 2. Mainshaft bearing retainer 3. Mainshaft
4. Reverse main gear 5. 1st main gear 6. Bushing
7. Needle bearing 8. 1st inner baulk ring 9. 1st gear synchronizer cone
10. 1st outer baulk ring 11. Spread spring 12. 1st & 2nd shifting insert
13. 1st & 2nd synchronizer hub 14. 2nd outer baulk ring 15. 2nd gear synchronizer cone
16. 2nd inner baulk ring 17. 1st & 2nd coupling sleeve 18. Bushing
19. Needle bearing 20. 2nd main gear 21. 3rd main gear
22. 3rd & 4th mainshaft spacer 23. 4th main adjusting shim 24. 4th main gear
25. 5th main gear 26. 6th main gear 27. Mainshaft rear bearing
31. Snap ring 32. Mainshaft rear bearing adjusting shim 33. 5th & 6th mainshaft spacer
34. 6th main adjusting shim
SCIA0957E
MT-148
[RS6F51H]
TRANSAXLE ASSEMBLY
1. Reverse shift fork 2. Shifter cap 3. Reverse fork rod
4. Reverse lever assembly 5. 5th & 6th bracket 6. 5th & 6th fork rod
7. 5th & 6th shift fork 8. Retaining pin 9. 3rd & 4th bracket
10. 3rd & 4th shift fork 11. 3rd & 4th fork rod 12. 1st & 2nd shift fork
13. 1st & 2nd bracket 14. 1st & 2nd fork rod 15. Shift check sleeve
16. Inter lock pin 17. Check ball 18. Shift check sleeve
19. Check spring 20. Check plug 21. Control assembly
22. O-ring 23. Shift check 24. Stopper bolt
25. Stopper ring 26. Reverse bracket fork rod 27. Reverse bracket
SCIA0958E
TRANSAXLE ASSEMBLY
MT-149
[RS6F51H]
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Disassembly and Assembly ECS005VF
DISASSEMBLY
1. Remove the drain plug and filler plug.
2. Remove the park/neutral position switch and back-up lamp
switch.
3. After removing the shift check and stopper bolt, remove the con-
trol assembly.
4. Remove the check plugs (4 pieces), check springs (4 pieces),
check balls (4 pieces), and shift check sleeve (2 pieces) as
shown.
1. Differential side bearing outer race 2. Differential side bearing 3. Speedometer drive gear
4. Differential case 5. Final gear 6. Differential side bearing
7. Differential side bearing outer race 8. Differential side bearing adjusting shim
WCIA0207E
SCIA0389E
SCIA0959E
MT-150
[RS6F51H]
TRANSAXLE ASSEMBLY
5. Remove the transaxle case fixing bolts as shown.
6. Remove the bore plug.
CAUTION:
Be careful not to damage transaxle case.
7. While spreading the snap ring of the mainshaft rear bearing located at bore plug hole, remove the tran-
saxle case.
8. Remove the oil gutter and baffle plate.
9. Remove the snap ring, mainshaft rear bearing adjusting shim, and input shaft rear bearing adjusting shim
from the transaxle case.
10. Remove the differential side bearing outer race (transaxle case
side) using Tool as shown, and then remove the adjusting shim.
11. Remove the welch plug with a suitable punch and hammer as
shown.
12. Remove the differential oil seal with a suitable tool as shown.
13. Remove the magnet from the clutch housing.
SCIA0983E
SCIA1021E
SCIA0402E
SCIA0397E
TRANSAXLE ASSEMBLY
MT-151
[RS6F51H]
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14. With the shift lever in 5th position, remove the bracket bolts from
the reverse lever assembly as shown. Lift the reverse lever
assembly to remove.
CAUTION:
Retain the shifter cap for installation.
15. Pull out the reverse fork rod then remove the reverse shift fork.
16. Remove the retaining pin of the reverse bracket.
17. Pull out the reverse lever and the reverse bracket fork rod.
18. Remove the check ball (2 pieces) and the interlock pin.
19. Shift the 3rd-4th fork rod to the 3rd position. Remove the retain-
ing pin of the 5th-6th shift fork using a pin punch.
20. Remove the stopper rings for the 5th-6th bracket.
21. Pull out the 5th-6th fork rod and remove the 5th-6th shift fork and the 5th-6th bracket.
22. Remove the check balls (2 pieces) and interlock pin.
SCIA0960E
SCIA0961E
SCIA0962E
SCIA0963E
MT-152
[RS6F51H]
TRANSAXLE ASSEMBLY
23. Remove the retaining pin of 3rd-4th bracket using pin punch.
24. Remove the stopper rings for 3rd-4th shift fork.
25. Pull out the 3rd-4th fork rod and remove 3rd-4th shift fork and bracket.
26. Remove the shift check sleeve from the clutch housing.
27. Remove the retaining pin of 1st-2nd shift fork using a suitable
pin punch.
28. Pull out the 1st-2nd fork rod with bracket.
29. Remove the 1st-2nd shift fork.
30. Remove the retaining pin of 1st-2nd bracket using a suitable pin punch and separate the fork rod and
bracket.
31. Remove the gear components from the clutch housing.
a. While tapping the input shaft with a plastic hammer, remove the
input shaft assembly, mainshaft assembly, and reverse idler
gear assembly as a set.
CAUTION:
Always withdraw the mainshaft straight out. Failure to do
so can damage the resin oil channel on the clutch housing
side.
b. Remove the final drive assembly.
32. Remove the bearing retainer and then the mainshaft front bear-
ing as shown.
33. Remove the oil channel on the mainshaft side.
SCIA0393E
SCIA0394E
SCIA0964E
SCIA0400E
TRANSAXLE ASSEMBLY
MT-153
[RS6F51H]
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34. Remove the differential oil seal (clutch housing side) using Tool
as shown.
35. Remove the differential side bearing outer race (clutch housing
side) using Tool as shown.
36. Remove the input shaft oil seal using a suitable tool as shown.
CAUTION:
Do not damage the clutch housing sealing surface.
ASSEMBLY
1. Install a new input shaft oil seal from the clutch housing end of
the side, to the depth of 1.8 - 2.8 mm (0.071 - 0.110 in) using
Tool (drift) as shown.
CAUTION:
SMT117E
SMT116E
SCIA0398E
SCIA1022E
MT-154
[RS6F51H]
TRANSAXLE ASSEMBLY
2. Install a new differential oil seal using Tool (drift) as shown.
CAUTION:
3. Install the oil channel on the mainshaft side as shown.
CAUTION:
Position the oil channel with the orientation as shown, for
installation.
4. Install the mainshaft front bearing using Tool (drift) as shown.
CAUTION:
Position the mainshaft front bearing with the orientation as
shown, for installation
5. Install the mainshaft front bearing retainer.
CAUTION:
Install the bearing retainer with the punched surface facing
up.
6. Install the differential side bearing outer race using Tool as
shown.
SCIA1023E
SCIA0986E
SCIA1024E
Bearing retainer bolt : 6.27 - 8.33 Nm (0.64 -
0.84 kg-m, 56 - 73 in-lb)
SCIA0400E
SCIA1063E
TRANSAXLE ASSEMBLY
MT-155
[RS6F51H]
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7. Install the final drive assembly into the clutch housing.
8. Install the input shaft assembly, mainshaft assembly, and
reverse idler gear assembly into the clutch housing.
CAUTION:
Do not damage the input shaft oil seal.
9. Install the 1st-2nd fork rod bracket onto the 1st-2nd fork rod, and
then install a new retaining pin as shown.
CAUTION:
10. Install the 1st-2nd fork rod and the 1st-2nd shift fork, and then
install a new retaining pin.
CAUTION:
11. Install the shift check sleeve.
12. Install the 3rd-4th bracket, 3rd-4th shift fork, and 3rd-4th fork rod with the interlock pin.
SCIA0888E
SCIA0964E
SCIA0889E
SCIA0394E
MT-156
[RS6F51H]
TRANSAXLE ASSEMBLY
13. Install the new stopper rings onto the 3rd-4th shift fork.
CAUTION:
14. Install a new retaining pin onto the 3rd-4th bracket.
CAUTION:
15. Install the 2 check balls.
16. Install the 5th-6th bracket, 5th-6th shift fork, and 5th-6th fork rod.
17. Install new stopper rings onto the 5th-6th bracket with interlock
pin.
CAUTION:
18. Install a new retaining pin onto the 5th-6th shift fork.
CAUTION:
19. Install the two check balls.
20. Install the reverse bracket fork rod and reverse lever bracket.
21. Install a new retaining pin onto the reverse bracket.
CAUTION:
22. Install the reverse shift fork and reverse fork rod.
23. Install the reverse lever assembly using the following steps:
a. Install the shifter cap onto the reverse lever assembly cam, and then install them onto the reverse shift
fork.
SCIA0393E
SCIA0963E
SCIA0962E
SCIA0961E
TRANSAXLE ASSEMBLY
MT-157
[RS6F51H]
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CAUTION:
Do not drop the shifter cap.
b. While lifting the reverse shift fork, align the cam with the reverse
bracket.
c. Tighten the bracket bolts to specification, and install the reverse
lever assembly.
24. Install the magnet onto the clutch housing.
25. Install the selected input shaft adjusting shim onto the input shaft.
G For selection of adjusting shims, refer to MT-160, "INPUTSHAFT END PLAY" .
26. Install the baffle plate and oil gutter.
27. Install the transaxle case using the following steps:
a. Install the selected mainshaft rear bearing adjusting shim into the transaxle case.
G For selection of adjusting shims, refer to MT-162, "MAINSHAFT END PLAY" .
b. Temporarily install the snap ring of the mainshaft rear bearing into the transaxle case.
CAUTION:
Do not reuse the snap ring.
c. Apply sealant to the mating surfaces of the transaxle case and
clutch housing as shown. Use Genuine Anaerobic Liquid Gasket
or equivalent. Refer to GI-44, "Recommended Chemical Prod-
ucts and Sealants" .
CAUTION:
Remove any old sealant adhering to the mounting surfaces.
Also remove any moisture, oil, or foreign material adhering
to the sealant application and mounting surfaces.
SCIA0965E
Bracket bolts : 11.8 - 15.6 Nm (1.2 - 1.5 kg-m,
9 - 11 ft-lb)
SCIA0960E
SCIA0891E
MT-158
[RS6F51H]
TRANSAXLE ASSEMBLY
d. Using a snap ring of the mainshaft rear bearing temporarily,
install the transaxle case over the clutch housing as shown.
e. Through the bore plug mounting hole, with the snap ring
stretched, lift up the mainshaft assembly from the control
assembly mounting hole.
f. Securely install the snap ring onto the mainshaft rear bearing as
shown.
g. Tighten the "A" bolts (gold) and new "B" bolts (black) to specifi-
cation.
CAUTION:
Always replace the "B" bolts as they are self-sealing bolts.
h. Install the control assembly using new O-rings.
CAUTION:
Do not reuse the O-ring.
i. Install a new shift check and a new stopper bolt.
CAUTION:
Shift check and stopper bolt are not reusable.
SCIA0892E
SCIA0893E
"A" Bolt : 50.0 - 53.9 N-m (5.1 - 5.4 kg-m, 37 - 39 ft-lb)
"B" Bolt : 63.0 - 66.9 N-m (6.5 - 6.8 kg-m, 47 - 49 ft-lb)
SCIA1064E
TRANSAXLE ASSEMBLY
MT-159
[RS6F51H]
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28. Install a new bore plug using Tool (drift) as shown.
CAUTION:
Bore plugs are not reusable.
29. Install the new welch plug using Tool (drift).
CAUTION:
Do not reuse the welch plug
30. Install the 2 shift check sleeves, 4 check balls, 4 check springs,
and 4 new check ball plugs.
CAUTION:
Check ball plugs are not reusable.
31. Apply sealant to the threads of the neutral switch and reverse
lamp switch. Then install them into the transaxle case. Refer to
MT-145, "CASE AND HOUSING COMPONENTS" . Use Genu-
ine Anaerobic Liquid Gasket or equivalent. Refer to GI-44, "Rec-
ommended Chemical Products and Sealants" .
32. Install new gaskets onto the drain plug and filler plug, and then install them into the transaxle case.
CAUTION:
G Gaskets are not reusable.
G After oil is filled, tighten filler plug to specification. Refer to MT-145, "CASE AND HOUSING
COMPONENTS" .
SCIA1025E
SMT131E
SCIA0959E
SCIA0895E
MT-160
[RS6F51H]
TRANSAXLE ASSEMBLY
Adjustment ECS005VG
INPUTSHAFT END PLAY
G When adjusting the input shaft end play, select the adjusting
shim for the input shaft bearing. To select the correct thickness
for the adjusting shim, measure the clearance between the tran-
saxle case and input shaft rear bearing.
G Calculate the dimension "O" (thickness of adjusting shim) using
the following steps to adjust the input shaft rear bearing for the
specified end play.
CAUTION:
Adjusting Shims
1. Using a depth micrometer and straight edge, measure the
dimension "O1 " between the transaxle case end face and
mounting face of the adjusting shim as shown.
SCIA1001E
End play : 0 - 0.06 mm (0 - 0.0024 in)
Dimension O = (O1 - O2 ) + End play
"O" : Thickness of adjusting shim
O1 : Distance between transaxle case end face and mounting face of adjusting shim
O2 : Distance between clutch housing case end face and end face of input shaft rear
bearing
Shim thickness Part number Shim thickness Part number Shim thickness Part number
0.40 mm (0.0157 in)
0.44 mm (0.0173 in)
0.48 mm (0.0189 in)
0.52 mm (0.0205 in)
0.56 mm (0.0220 in)
0.60 mm (0.0236 in)
0.64 mm (0.0252 in)
0.68 mm (0.0268 in)
0.72 mm (0.0283 in)
0.76 mm (0.0299 in)
0.80 mm (0.0315 in)
0.84 mm (0.0331 in)
32225 8H500
32225 8H501
32225 8H502
32225 8H503
32225 8H504
32225 8H505
32225 8H506
32225 8H507
32225 8H508
32225 8H509
32225 8H510
32225 8H511
0.88 mm (0.0346 in)
0.92 mm (0.0362 in)
0.96 mm (0.0378 in)
1.00 mm (0.0396 in)
1.04 mm (0.0409 in)
1.08 mm (0.0425 in)
1.12 mm (0.0441 in)
1.16 mm (0.0457 in)
1.20 mm (0.0472 in)
1.24 mm (0.0488 in)
1.28 mm (0.0504 in)
1.32 mm (0.0520 in)
32225 8H512
32225 8H513
32225 8H514
32225 8H515
32225 8H516
32225 8H517
32225 8H518
32225 8H519
32225 8H520
32225 8H521
32225 8H522
32225 8H523
1.36 mm (0.0520 in)
1.40 mm (0.0551 in)
1.44 mm (0.0567 in)
1.48 mm (0.0583 in)
1.52 mm (0.0598 in)
1.56 mm (0.0614 in)
1.60 mm (0.0630 in)
1.64 mm (0.0646 in)
32225 8H524
32225 8H560
32225 8H561
32225 8H562
32225 8H563
32225 8H564
32225 8H565
32225 8H566
SCIA1002E
TRANSAXLE ASSEMBLY
MT-161
[RS6F51H]
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dimension "O2 " between the clutch housing case end face and
end face of the input shaft rear bearing as shown.
3. Install the selected input shaft rear bearing adjusting shim onto the input shaft.
DIFFERENTIAL SIDE BEARING PRELOAD
G When adjusting differential side bearing preload, select adjust-
ing shim for differential side bearing. To select adjusting shim,
measure clearance L between transaxle case and differential
side bearing outer race.
G Calculate dimension L (thickness of adjusting shim) using the
following procedure to meet specification of preload for differen-
tial side bearing.
CAUTION:
Up to only 2 adjusting shims can be selected.
Adjusting Shim
dimension "L1 " between the clutch housing case end face and
SCIA1004E
Preload : 0.15 - 0.21 mm (0.0059 - 0.0083 in)
Dimension L = (L1 - L2 ) + Preload
"L" : Thickness of adjusting shim
L1 : Distance between clutch housing case end
face and mounting face of adjusting shim
L2 : Distance between differential side bearing
and transaxle case
SCIA0896E
0.48 mm (0.0189 in)
0.52 mm (0.0205 in)
0.56 mm (0.0220 in)
0.60 mm (0.0236 in)
0.64 mm (0.0252 in)
0.68 mm (0.0268 in)
0.72 mm (0.0283 in)
0.76 mm (0.0299 in)
0.80 mm (0.0315 in)
0.84 mm (0.0331 in)
0.88 mm (0.0346 in)
0.92 mm (0.0362 in)
31438 80X00
31438 80X01
31438 80X02
31438 80X03
31438 80X04
31438 80X05
31438 80X06
31438 80X07
31438 80X08
31438 80X09
31438 80X10
31438 80X11
SCIA1078E
MT-162
[RS6F51H]
TRANSAXLE ASSEMBLY
2. Install the outer race onto the differential side bearing on the final gear side. Holding the outer race hori-
zontally by hand, rotate the final gear five times or more (for smooth movement of the bearing roller).
dimension "L2 " between the differential side bearing outer race
and transaxle case end face as shown.
4. Install the selected adjusting shim and then the differential side
bearing outer race using Tool as shown.
MAINSHAFT END PLAY
G When adjusting the mainshaft end play, select the adjusting
shim for the mainshaft rear bearing. To select the adjusting
shim, measure clearance M between the transaxle case and
mainshaft rear bearing.
G Calculate the dimension "P" (thickness of adjusting shim) using
the following procedure to meet specification of end play for
mainshaft rear bearing.
CAUTION:
SCIA1079E
SCIA1026E
End play : 0 - 0.06 mm (0 - 0.0024 in)
Dimension P = "M" + End play
"P" : Thickness of adjusting shim
"M" : Distance between mainshaft rear bearing
and transaxle case
SCIA0904E
TRANSAXLE ASSEMBLY
MT-163
[RS6F51H]
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Adjusting Shim
1. Install the mainshaft assembly to the clutch housing.
2. Install the snap ring to the transaxle case.
3. Install the transaxle case to clutch housing, and temporarily assemble them with fixing bolts. Temporarily
install the snap ring to the mainshaft rear bearing.
4. Install the dial gauge to the snap ring access hole, and expand
the snap ring as shown. Lift the mainshaft assembly through the
control assembly installation hole, and push it against the tran-
saxle case. This state shall be defined as base. Moving the dis-
tance of the mainshaft assembly, with the snap ring installed on
the main bearing, becomes M.
REVERSE IDLER GEAR END PLAY
G When adjusting the reverse idler gear end play, select the
adjusting shim for the reverse idler gear. To select the correct
thickness of adjusting shim, measure the clearance between the
transaxle case and reverse idler gear.
G Calculate the dimension "Q" (thickness of adjusting shim) using
the following steps to adjust the end play of the reverse idler
gear to specification.
CAUTION:
0.44 mm (0.0173 in)
0.48 mm (0.0189 in)
0.52 mm (0.0205 in)
0.56 mm (0.0220 in)
0.60 mm (0.0236 in)
0.64 mm (0.0252 in)
0.68 mm (0.0268 in)
0.72 mm (0.0283 in)
0.76 mm (0.0299 in)
0.80 mm (0.0315 in)
0.84 mm (0.0331 in)
0.88 mm (0.0346 in)
0.92 mm (0.0362 in)
0.96 mm (0.0378 in)
1.00 mm (0.0396 in)
1.04 mm (0.0409 in)
1.08 mm (0.0425 in)
32238 8H510
32238 8H511
32238 8H512
32238 8H513
32238 8H514
32238 8H515
32238 8H516
32238 8H517
32238 8H518
32238 8H519
32238 8H520
32238 8H521
32238 8H522
32238 8H523
32238 8H524
32238 8H560
32238 8H561
SCIA1017E
End play : 0.04 - 0.14 mm (0.0016 - 0.0055 in)
Dimension Q = (Q1 - Q2 ) + End play
"Q" : Thickness of adjusting shim
Q1 : Distance between transaxle case end face
Q2 : Distance between clutch housing case end
face and end face of reverse idler gear
SCIA1007E
MT-164
[RS6F51H]
TRANSAXLE ASSEMBLY
Adjusting Shim
dimension "Q1 " between the transaxle case end face and the
dimension "Q2 " between the clutch housing case end face and
the end face of reverse idler gear as shown.
3. Install the selected reverse idler gear adjusting shim onto the reverse idler gear.
1.76 mm (0.0693 in)
1.84 mm (0.0724 in)
1.92 mm (0.0756 in)
2.00 mm (0.0787 in)
2.08 mm (0.0819 in)
2.16 mm (0.0850 in)
2.24 mm (0.0882 in)
2.32 mm (0.0913 in)
2.40 mm (0.0945 in)
2.48 mm (0.0976 in)
2.56 mm (0.1008 in)
2.64 mm (0.1039 in)
32237 8H500
32237 8H501
32237 8H502
32237 8H503
32237 8H504
32237 8H505
32237 8H506
32237 8H507
32237 8H508
32237 8H509
32237 8H510
32237 8H511
SCIA1003E
SCIA1005E
MT-165
[RS6F51H]
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Disassembly and Assembly ECS005VH
DISASSEMBLY
1. Before disassembling, measure the end play for 3rd, 4th, 5th,
and 6th input gears.
CAUTION:
If measurement is outside the standard value, disassemble
to check the contact surfaces of the gear, shaft, and, hub.
Adjust using the correct size snap ring for assembly.
2. Remove the oil channel.
3. Remove the input shaft rear bearing using Tool as shown.
5. Remove the 6th input gear, 6th bushing, and 6th needle bearing
6. Remove the 6th baulk ring, 5th-6th coupling sleeve, and shifting
insert.
7. Remove the 5th input gear and synchronizer hub assembly
simultaneously using Tool as shown.
8. Remove the 5th needle bearing.
End play standard values
3rd gear : 0.18 - 0.31 mm (0.0071 - 0.0122 in)
4th gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)
5th gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
6th gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
SCIA0966E
SCIA1037E
SCIA1038E
SMT137E
MT-166
[RS6F51H]
9. Remove the 5th bushing, thrust washer, 4th input gear, 4th nee-
dle bearing, 4th bushing, 4th baulk ring, 3rd-4th synchronizer
hub assembly, 3rd baulk ring, and 3rd input gear simultaneously
10. Remove the 3rd needle bearing.
11. Remove the input shaft front bearing using Tool as shown.
Input Shaft and Gears
Inspect the components for the following conditions as shown. If
necessary, replace them with new ones.
G Damage, peeling, dent, uneven wear, or bending of the input
shaft.
G Excessive wear, damage, or peeling of the input gears.
Synchronizer
Check the items below. If necessary, replace them with new ones.
G Damage and excessive wear of the contact surfaces of coupling
sleeve, synchronizer hub, and shifting insert.
G Coupling sleeve and synchronizer hub must move smoothly as
shown.
SCIA1030E
SCIA0920E
LCIA0308E
SMT387A
MT-167
[RS6F51H]
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G If any cracks, damage, or excessive wear is found on the cam
face of baulk ring or working face of the insert as shown, replace
it.
G Press the baulk ring against cone, and measure clearance
between baulk ring and cone. If measurement is below limit,
replace it with a new one.
Bearing
G Damage and rough rotation of the bearing as shown.
ASSEMBLY
1. Install the 3rd needle bearing.
2. Install the 3rd input gear and 3rd baulk ring.
3. Install the spread spring, shifting insert, and a new 3rd-4th synchronizer hub onto the 3rd-4th coupling
sleeve.
CAUTION:
G Install with orientation of the synchronizer hub as shown.
G Do not reuse the 3rd-4th synchronizer hub.
SMT867D
Clearance - standard
3rd and 4th : 0.9 - 1.45 mm (0.035 - 0.0571 in)
5th and 6th : 0.95 - 1.4 mm (0.0374 - 0.055 in)
Limit : 0.7 mm (0.028 in)
SMT140
MTF0041D
SCIA0921E
MT-168
[RS6F51H]
G Be sure not to hook the ends of the 2 spread springs
(front and back have two each) on the same shifting
insert.
4. Install 3rd-4th synchronizer hub assembly using Tool as shown.
CAUTION:
Align grooves of shifting insert and 3rd baulk ring.
5. Install the 4th bushing using Tool as shown.
6. Install the 4th baulk ring.
7. Install the 4th input gear and 4th needle bearing.
SCIA0993E
SCIA1083E
SCIA1031E
SCIA1032E
MT-169
[RS6F51H]
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8. Measure the dimension C2 as shown. Select a thrust washer
so that dimension C2 satisfies standard dimension specifica-
tion. Then install the thrust washer onto the input shaft.
CAUTION:
Only 1 thrust washer can be selected.
Thrust Washer
9. Install the 5th bushing using Tool as shown.
10. Install the 5th needle bearing and 5th input gear.
11. Install the 5th baulk ring.
12. Install the synchronizer assembly onto a new 5th-6th synchro-
nizer hub.
CAUTION:
G Install with the orientation of the synchronizer hub as
shown.
G Do not reuse the 5th-6th synchronizer hub.
(6.091 - 6.094 in)
SCIA0925E
3.84 mm (0.1512 in)
3.90 mm (0.1535 in)
3.96 mm (0.1559 in)
32347 8H500
32347 8H501
32347 8H502
4.02 mm (0.1583 in)
4.08 mm (0.1606 in)
4.14 mm (0.1630 in)
32347 8H503
32347 8H504
32347 8H505
SCIA1033E
SCIA0921E
MT-170
[RS6F51H]
G Be sure not to hook the ends of the 2 spread springs
(front and back have two each) on the same shifting
insert.
13. Install the 5th-6th synchronizer hub assembly using Tool as
shown.
CAUTION:
Align the grooves of the 5th-6th shifting insert and 5th-6th
baulk ring.
14. Install the needle bearing, 6th input gear and then 6th bushing
15. Install the snap ring onto the input shaft, and measure to check
that end play (gap between snap ring and groove) of the 6th
bushing is within specification.
G If the measurement is outside the standard value, select the
appropriate size snap ring.
Snap Rings
SCIA1083E
SCIA1039E
SCIA1040E
SCIA0970E
1.76 mm (0.0693 in)
1.81 mm (0.0713 in)
1.86 mm (0.0732 in)
1.91 mm (0.0752 in)
1.96 mm (0.0772 in)
32204 8H511
32204 8H512
32204 8H513
32204 8H514
32204 8H515
2.01 mm (0.0791 in)
2.06 mm (0.0811 in)
2.11 mm (0.0831 in)
2.16 mm (0.0850 in)
2.21 mm (0.0871 in)
32204 8H516
32204 8H517
32204 8H518
32204 8H519
32204 8H520
MT-171
[RS6F51H]
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16. Install the input shaft rear bearing using Tool as shown.
CAUTION:
17. Install the input shaft front bearing using Tool as shown.
18. Install the oil channel onto the input shaft.
19. Check the end play of the 3rd, 4th, 5th and 6th input gears as
shown.
SCIA1041E
SCIA1042E
3rd gear : 0.18 - 0.31 mm (0.0071 - 0.0122 in)
4th gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)
5th gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
6th gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
SCIA0966E
MT-172
[RS6F51H]
MAINSHAFT AND GEARS
Disassembly and Assembly ECS005VI
DISASSEMBLY
1. Before disassembling, measure the end play of 1st and 2nd
main gears as shown.
CAUTION:
If the measurement is outside the standard value, disas-
semble to check the contact surfaces of gear, shaft, and
hub. Adjust with the snap ring at assembly.
3. Remove the C-ring holder, and then mainshaft C-ring as shown.
4. Remove the mainshaft rear bearing, adjust shim, and 6th main
gear using Tool as shown.
5. Remove the 5th-6th mainshaft spacer.
6. Remove the 4th main gear and 5th main gear simultaneously
7. Remove the adjusting shim.
8. Remove the 3rd-4th mainshaft spacer.
1st gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)
2nd gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
SCIA0973E
SCIA0974E
SCIA1056E
SCIA1044E
MAINSHAFT AND GEARS
MT-173
[RS6F51H]
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9. Remove the 3rd main gear, 2nd main gear, 2nd gear needle
bearing, 2nd bushing, 1st-2nd synchronizer assembly, 1st main
gear, reverse main gear, 1st gear needle bearing, and 1st bush-
ing simultaneously using Tool as shown.
Mainshaft and Gears
Check the items listed as shown. If necessary, replace them with
new ones.
standard conditions of the mainshaft.
ditions of the mainshaft gears.
Synchronizer
Check the items listed as shown. If necessary, replace them with
new ones.
G Damage, unusual wear on contact surfaces of coupling sleeve,
synchronizer hub, and shifting insert.
shown.
G If any cracks, damage, or excessive wear is found on the cam
face of baulk ring or working face of the insert, replace it.
SCIA1045E
LCIA0309E
SMT387A
SMT867D
MT-174
[RS6F51H]
MAINSHAFT AND GEARS
Checking the double cone synchronizer (1st-2nd)
G Check the clearance of outer baulk ring, synchronizer cone, and
inner baulk ring of 1st-2nd double cone synchronizer, using the
following steps.
NOTE:
The mean value is the middle value of a set of measurements
between the highest and lowest values. It is calculated by add-
ing the highest and lowest measured value and dividing their
sum by two: [(high value) + (low value)] / 2 = mean value.
CAUTION:
Outer baulk ring, synchronizer cone, and inner baulk ring
act as a set to control the clearances A and B. If the
measurement exceeds the service limit value, replace all of them as a set.
1. Using a dial gauge and Tool, measure clearance A at two or
more points diagonally opposite, and calculate mean value.
2. Using a feeler gauge, measure clearance B at two or more
points diagonally opposite, and calculate mean value as shown.
Bearing
G Damage and rough rotation of the bearing as shown.
SMT138E
Clearance A
Standard : 0.6 - 0.8 mm (0.024 - 0.031 in)
SCIA1046E
Clearance B
Standard : 0.6 - 1.1 mm (0.024 - 0.043 in)
SCIA1084E
MTF0041D
MAINSHAFT AND GEARS
MT-175
[RS6F51H]
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ASSEMBLY
1. Install the reverse main gear using Tool as shown.
CAUTION:
Install with the orientation of reverse main gear as shown.
2. Install the 1st bushing using Tool as shown.
3. Install the needle bearing, and then the 1st main gear.
4. Install the spread spring, shifting insert, and a new 1st-2nd synchronizer hub onto the 1st-2nd coupling
sleeve.
CAUTION:
G Install with the orientation of the new synchronizer hub
as shown.
G Do not reuse 1st-2nd synchronizer hub
SCIA1048E
SCIA0992E
SCIA1049E
SCIA0921E
MT-176
[RS6F51H]
MAINSHAFT AND GEARS
G Install with the orientation of coupling sleeve as shown.
G Do not hook the ends of the two spread springs (front
and back have two each) on the same shifting insert.
5. Install the 1st gear synchronizer assembly onto the mainshaft,
and the synchronizer hub assembly onto the mainshaft using
Tool as shown.
CAUTION:
G Outer baulk ring, synchronizer cone, and inner baulk ring
on the 2nd gear-side must have been removed.
G Install the coupling sleeve with the proper orientation.
6. Install the 2nd bushing using Tool as shown.
7. Install the outer baulk ring, synchronizer cone, and inner baulk
ring on 2nd gear-side.
8. Install the 2nd needle bearing and 2nd gear.
9. Install the 3rd main gear.
CAUTION:
Install the 3rd main gear with the orientation as shown.
10. Install the 3rd-4th mainshaft spacer.
SCIA0989E
SCIA1083E
SCIA1050E
SCIA1051E
SCIA1052E
MAINSHAFT AND GEARS
MT-177
[RS6F51H]
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11. Measure the dimension C1 . Select a suitable adjusting shim
so that the dimension C1 satisfies the specified standard
value, and install it onto the mainshaft.
CAUTION:
Adjusting Shim
12. Install the 4th main gear with the specified orientation as shown,
CAUTION:
Install the 4th main gear with the orientation as shown.
13. Install the 5th main gear with the specified orientation as shown,
CAUTION:
Install the 5th main gear with the orientation as shown.
14. Install the 5th-6th mainshaft spacer.
Standard for dimension C1
: 173.85 - 173.95 mm
(6.844 - 6.848 in)
SCIA0944E
0.52 mm (0.0205 in)
0.60 mm (0.0236 in)
0.68 mm (0.0268 in)
0.76 mm (0.0299 in)
32238 8H500
32238 8H501
32238 8H502
32238 8H503
0.84 mm (0.0331 in)
0.92 mm (0.0362 in)
1.00 mm (0.0394 in)
1.08 mm (0.0425 in)
32238 8H504
32238 8H505
32238 8H506
32238 8H507
SCIA1053E
SCIA1054E
MT-178
[RS6F51H]
MAINSHAFT AND GEARS
15. Install the 6th main gear using Tool as shown.
16. Select the 6th main adjusting shim and then install it onto the mainshaft.
G Calculate thickness S of 6th main adjusting shim by proce-
dure below so that end play dimension between 6th main
gear and mainshaft rear bearing becomes the dimension
specified.
CAUTION:
Adjusting Shim
a. Using a height gauge, measure the dimension S1 and S2 as shown.
b. Install the selected 6th main adjusting shim to the mainshaft.
17. Install the mainshaft rear bearing using Tool as shown.
SCIA1057E
End play : 0 - 0.1 mm (0 - 0.004 in)
Dimension S = (S1 - S2 ) + end play
S : Thickness of adjusting shim
S1 : Dimension from mainshaft standard face to
mainshaft rear bearing press-fit end face
S2 : Dimension from mainshaft standard face to
6th main gear end face
SCIA0995E
0.88 mm (0.0346 in)
0.96 mm (0.0378 in)
1.04 mm (0.0409 in)
1.12 mm (0.0441 in)
32237 8H560
32237 8H561
32237 8H562
32237 8H563
1.20 mm (0.0472 in)
1.28 mm (0.0504 in)
1.36 mm (0.0535 in)
32237 8H564
32237 8H565
32237 8H566
SCIA1058E
MAINSHAFT AND GEARS
MT-179
[RS6F51H]
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18. Install the C-ring onto the mainshaft, and check that the end play
of mainshaft rear bearing meets specifications.
G If the measurement is outside the specified standard value,
reselect a new C-ring.
C-Ring
19. Fit the C-ring holder, and install the snap ring as shown.
20. Check the end play of 1st and 2nd main gears as shown.
SCIA0979E
2.535 mm (0.0866 in)
2.565 mm (0.1010 in)
2.595 mm (0.1022 in)
2.625 mm (0.1033 in)
2.655 mm (0.1045 in)
2.685 mm (0.1057 in)
2.715 mm (0.1069 in)
2.745 mm (0.1081 in)
2.775 mm (0.1093 in)
2.805 mm (0.1104 in)
32348 8H800
32348 8H801
32348 8H802
32348 8H803
32348 8H804
32348 8H805
32348 8H806
32348 8H807
32348 8H808
32348 8H809
2.835 mm (0.1116 in)
2.865 mm (0.1128 in)
2.895 mm (0.1140 in)
2.925 mm (0.1152 in)
2.955 mm (0.1163 in)
2.985 mm (0.1175 in)
3.015 mm (0.1187 in)
3.045 mm (0.1199 in)
3.075 mm (0.1211 in)
32348 8H810
32348 8H811
32348 8H812
32348 8H813
32348 8H814
32348 8H815
32348 8H816
32348 8H817
32348 8H818
SCIA0974E
1st gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)
2nd gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
SCIA0973E
MT-180
[RS6F51H]
REVERSE IDLER SHAFT AND GEARS PFP:32281
Disassembly and Assembly ECS005VJ
DISASSEMBLY
1. Remove the reverse idler gear adjusting shim.
2. Remove the reverse idler gear (rear), reverse coupling sleeve and insert spring simultaneously.
3. Remove the reverse idler gear needle bearing.
4. Remove the thrust needle bearing.
5. Remove the reverse baulk ring.
6. Remove the reverse idler gear (front).
7. Remove the reverse idler gear needle bearing.
8. Remove the thrust needle bearing.
9. Pull off the locking pin from the reverse idler shaft.
Reverse Idler Shaft and Gears
Check the parts listed. If necessary, replace them with new ones.
standard conditions of the reverse idler shaft.
ditions of the reverse idler gears.
Synchronizer
sleeve, synchronizer hub, and insert spring.
shown.
SCIA0953E
SMT637A
SMT867D
MT-181
[RS6F51H]
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Baulk ring clearance
G Press the baulk ring against the cone, and measure the clear-
ance between the baulk ring and cone as shown. If the mea-
surement is below the specified limit, replace it with a new one.
Bearing
Check the parts listed. If necessary, replace them with new ones.
G Damage and rough rotation of the bearing.
ASSEMBLY
Assembly is in the reverse order of disassembly.
CAUTION:
G Install the insert spring with the orientation as shown.
Baulk ring to gear clearance
Standard : 0.95 - 1.4 mm (0.0374 - 0.055 in)
SMT140
SCIA0954E
MT-182
[RS6F51H]
FINAL DRIVE
Disassembly and Assembly ECS005VK
DISASSEMBLY
1. Remove the final gear bolts. Then, separate the final gear from the differential case.
2. Remove the speedometer drive gear.
3. Using a puller and Tool (drift), remove the differential side bear-
ing (clutch housing side) as shown.
4. Using a puller and Tool (drift), remove the differential side bear-
ing (transaxle case side) as shown.
Bearing
G Check for bearing damage and rough rotation as shown. If nec-
essary, replace with a new one.
CAUTION:
When replacing the tapered roller bearing, replace the outer and
inner races as a set.
ASSEMBLY
1. Using Tool (drift), install the differential side bearing (transaxle
case side) as shown.
SCIA1019E
SCIA1060E
SPD715
SCIA1061E
FINAL DRIVE
MT-183
[RS6F51H]
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MT
2. Align and install the speedometer drive gear onto the differential
case as shown.
3. Using Tool (drift), install the differential side bearing (clutch
housing side) as shown.
4. Install the final gear into the differential case, and tighten the
final gear bolts to specification.
SMT842D
SCIA1018E
COMPONENTS" .
SCIA0912E
MT-184
[RS6F51H]
SHIFT CONTROL
Inspection ECS005VL
G Check the contact surfaces and sliding area for wear, damage,
or bending as shown. If necessary, replace the parts.
SHIFT FORK
G Check if the width of the shift fork hook (sliding area with cou-
pling sleeve) is within specification, as shown.
Shift Fork
SCIA0913E
SMT801D
Item One-side wear specification Sliding width of new part
1st & 2nd 0.2 mm (0.008 in)
7.80 - 7.93 mm
(0.3071 - 0.3122 in)
3rd & 4th 0.2 mm (0.008 in)
7.80 - 7.93 mm
(0.3071 - 0.3122 in)
5th & 6th 0.2 mm (0.008 in)
6.10 - 6.23 mm
(0.2402 - 0.2453 in)
Reverse 0.2 mm (0.008 in)
12.80 - 12.93 mm
(0.5039 - 0.5091 in)
MT-185
[RS6F51H]
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General Specifications ECS005VM
TRANSAXLE
Engine QR25DE
Transaxle model RS6F51H
Number of speed 6
Shift pattern
2nd 1.944
3rd 1.392
4th 1.055
5th 0.809
6th 0.673
Reverse 3.002
2nd 18
3rd 28
4th 36
5th 42
6th 46
Reverse 13
Main gear 1st 41
2nd 35
3rd 39
4th 38
5th 34
6th 29
Reverse 38
Reverse idler gear
Front 37
Rear 38
Remarks
Reverse synchronizer Installed
Double baulk ring type synchronizer 1st & 2rd synchronizer
SCIA0955E
MT-186
[RS6F51H]
FINAL GEAR
Gear End Play ECS005VN
Unit: mm (in)
Clearance Between Baulk Ring and Gear ECS005VO
3RD, 4TH, 5TH, 6TH & REVERSE BAULK RING
Unit: mm (in)
1ST AND 2ND DOUBLE BAULK RING
Unit: mm (in)
Engine QR25DE
Transaxle model RS6F51H
Number of teeth Final gear/Pinion 62/15
Side gear/Pinion mate gear
Gear End play
1st main gear 0.20 - 0.30 (0.0079 - 0.0118)
2nd main gear 0.06 - 0.16 (0.0024 - 0.0063)
3rd input gear 0.18 - 0.31 (0.0071 - 0.0122)
4th input gear 0.20 - 0.30 (0.0079 - 0.0118)
5th input gear 0.06 - 0.16 (0.0024 - 0.0063)
6th input gear 0.06 - 0.16 (0.0024 - 0.0063)
Standard Wear limit
3rd 0.9 - 1.45 (0.035 - 0.0571) 0.7 (0.028)
4th 0.9 - 1.45 (0.035 - 0.0571) 0.7 (0.028)
5th 0.95 - 1.4 (0.0374 - 0.055) 0.7 (0.028)
6th 0.95 - 1.4 (0.0374 - 0.055) 0.7 (0.028)
Reverse 0.95 - 1.4 (0.0374 - 0.055) 0.7 (0.028)
A 0.6 - 0.8 (0.024 - 0.031) 0.2 (0.008)
B 0.6 - 1.1 (0.024 - 0.043) 0.2 (0.008)
SMT138E
MT-187
[RS6F51H]
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MT
Available Snap Rings ECS005VP
6TH BUSHING
Available C-rings ECS005VQ
MAINSHAFT C-RING
Available Thrust Washers ECS005VR
INPUT SHAFT THRUST WASHER
End play 0 - 0.1 mm (0 - 0.004 in)
1.76 (0.0693)
1.81 (0.0713)
1.86 (0.0732)
1.91 (0.0752)
1.96 (0.0772)
32204 8H511
32204 8H512
32204 8H513
32204 8H514
32204 8H515
2.01 (0.0791)
2.06 (0.0811)
2.11 (0.0831)
2.16 (0.0850)
2.21 (0.0871)
32204 8H516
32204 8H517
32204 8H518
32204 8H519
32204 8H520
End play 0 - 0.06 mm (0 - 0.0024 in)
2.535 (0.0866)
2.565 (0.1010)
2.595 (0.1022)
2.625 (0.1033)
2.655 (0.1045)
2.685 (0.1057)
2.715 (0.1069)
2.745 (0.1081)
2.775 (0.1093)
2.805 (0.1104)
32348 8H800
32348 8H801
32348 8H802
32348 8H803
32348 8H804
32348 8H805
32348 8H806
32348 8H807
32348 8H808
32348 8H809
2.835 (0.1116)
2.865 (0.1128)
2.895 (0.1140)
2.925 (0.1152)
2.955 (0.1163)
2.985 (0.1175)
3.015 (0.1187)
3.045 (0.1199)
3.075 (0.1211)
32348 8H810
32348 8H811
32348 8H812
32348 8H813
32348 8H814
32348 8H815
32348 8H816
32348 8H817
32348 8H818
3.84 (0.1512)
3.90 (0.1535)
3.96 (0.1559)
32347 8H500
32347 8H501
32347 8H502
4.02 (0.1583)
4.08 (0.1606)
4.14 (0.1630)
32347 8H503
32347 8H504
32347 8H505
SCIA1008E
MT-188
[RS6F51H]
Available Adjusting Shims ECS005VS
0.52 (0.0205)
0.60 (0.0236)
0.68 (0.0268)
0.76 (0.0299)
32238 8H500
32238 8H501
32238 8H502
32238 8H503
0.84 (0.0331)
0.92 (0.0362)
1.00 (0.0394)
1.08 (0.0425)
32238 8H504
32238 8H505
32238 8H506
32238 8H507
SCIA1009E
End play 0 - 0.06 mm (0 - 0.0024 in)
Thickness mm (in) Part number* Thickness mm (in) Part number* Thickness mm (in) Part number*
0.40 (0.0157)
0.44 (0.0173)
0.48 (0.0189)
0.52 (0.0205)
0.56 (0.0220)
0.60 (0.0236)
0.64 (0.0252)
6.68 (0.0268)
0.72 (0.0283)
0.76 (0.0299)
0.80 (0.0315)
0.84 (0.0331)
32225 8H500
32225 8H501
32225 8H502
32225 8H503
32225 8H504
32225 8H505
32225 8H506
32225 8H507
32225 8H508
32225 8H509
32225 8H510
32225 8H511
0.88 (0.0346)
0.92 (0.0362)
0.96 (0.0378)
1.00 (0.0396)
1.04 (0.0409)
1.08 (0.0425)
1.12 (0.0441)
1.16 (0.0457)
1.20 (0.0472)
1.24 (0.0488)
1.28 (0.0504)
1.32 (0.0520)
32225 8H512
32225 8H513
32225 8H514
32225 8H515
32225 8H516
32225 8H517
32225 8H518
32225 8H519
32225 8H520
32225 8H521
32225 8H522
32225 8H523
1.36 (0.0520)
1.40 (0.0551)
1.44 (0.0567)
1.48 (0.0583)
1.52 (0.0598)
1.56 (0.0614)
1.60 (0.0630)
1.64 (0.0646)
32225 8H524
32225 8H560
32225 8H561
32225 8H562
32225 8H563
32225 8H564
32225 8H565
32225 8H566
End play 0 - 0.06 mm (0 - 0.0024 in)
0.44 (0.0173)
0.48 (0.0189)
0.52 (0.0205)
0.56 (0.0220)
0.60 (0.0236)
0.64 (0.0252)
0.68 (0.0268)
0.72 (0.0283)
0.76 (0.0299)
32238 8H510
32238 8H511
32238 8H512
32238 8H513
32238 8H514
32238 8H515
32238 8H516
32238 8H517
32238 8H518
0.80 (0.0315)
0.84 (0.0331)
0.88 (0.0346)
0.92 (0.0362)
0.96 (0.0378)
1.00 (0.0396)
1.04 (0.0409)
1.08 (0.0425)
32238 8H519
32238 8H520
32238 8H521
32238 8H522
32238 8H523
32238 8H524
32238 8H560
32238 8H561
MT-189
[RS6F51H]
D
E
F
G
H
I
J
K
L
M
A
B
MT
REVERASE IDLER GEAR ADJUSTING SHIM
6TH MAIN GEAR ADJUSTING SHIM
Available Shims ECS005VT
Differential Side Bearing Preload and Adjusting Shim
BEARING PRELOAD
*: Install shims which are deflection of differential case + L in thickness.
DIFFERENTIAL SIDE BEARING ADJUSTING SHIM(S)
End play 0.04 - 0.14 mm (0.0016 - 0.0055 in)
1.76 (0.0693)
1.84 (0.0724)
1.92 (0.0756)
2.00 (0.0787)
2.08 (0.0819)
2.16 (0.0850)
32237 8H500
32237 8H501
32237 8H502
32237 8H503
32237 8H504
32237 8H505
2.24 (0.0882)
2.32 (0.0913)
2.40 (0.0945)
2.48 (0.0976)
2.56 (0.1008)
2.64 (0.1039)
32237 8H506
32237 8H507
32237 8H508
32237 8H509
32237 8H510
32237 8H511
End play 0 - 0.1 mm (0 - 0.004 in)
0.88 (0.0346)
0.96 (0.0378)
1.04 (0.0409)
1.12 (0.0441)
32237 8H560
32237 8H561
32237 8H562
32237 8H563
1.20 (0.0472)
1.28 (0.0504)
1.36 (0.0520)

32237 8H564
32237 8H565
32237 8H566
Differential side bearing preload: L* 0.15 - 0.21 mm (0.0059 - 0.0083)
0.48 (0.0189)
0.52 (0.0205)
0.56 (0.0220)
0.60 (0.0236)
0.64 (0.0252)
0.68 (0.0268)
31438 80X00
31438 80X01
31438 80X02
31438 80X03
31438 80X04
31438 80X05
0.72 (0.0283)
0.76 (0.0299)
0.80 (0.0315)
0.84 (0.0331)
0.88 (0.0346)
0.92 (0.0362)
31438 80X06
31438 80X07
31438 80X08
31438 80X09
31438 80X10
31438 80X11
MT-190
[RS6F51H]

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